Upload
amir-shahmi
View
249
Download
3
Embed Size (px)
Citation preview
EZTECH
2015
EASYTECH SDN BHD
DOMESTIC AND INDUSTRIAL WIR ING INSTALLATION GUIDE
PREPARED BY EASYTECH
EZTECH ELECTRICAL INSTALLATION GUIDE
Table of ContentsELECTRICITY SUPPLY SPECIFICATIONS4
Legal Requirements5
Determining Consumer Load Requirements6
2 CONTROL AND PROTECTION SYSTEM FOR ELECTRICAL WIRING7
CABLE SELECTION10
32 Factors Related to Cable Current Carrying Capacity11
Functions and Colour Identification of Non Flexible Cables12
Conductor Insulation and Types of Wiring13
Functions and Colour Identification of Non Flexible Cables13
3 SELECTION OF WIRING ACCESSORIES13
EARTHING OF ELECTRICAL INSTALLATIONS15
4 SAFETY REQUIREMENTS FOR ELECTRICAL WIRING WORKS IN
RESIDENTIAL BUILDINGS18
Why Electric Shocks Occur19
INSTALLATION CIRCUITS AND SYSTEMS20
Working Principal of Star-Delta Starter21
Star-delta Starter Consists following units21
Power Circuit of Star Delta Starter21
Control Circuit of Star-Delta Starter (Open Transition)22
What is Open or Closed Transition Starting23
Effect of Transient in Starter (Open Transient starter)25
Size of each part of Star-Delta starter25
Motor Starting Characteristics of Star-Delta Starter26
Advantages of Star-Delta starter26
Disadvantages of Star-Delta starter26
Features of star-delta starting27
Application of Star-Delta Starter27
28
LESSON 1 WIRING SYSTEM OF SINGLE PHASE DISTRIBUTION BOARD28
LESSON 2 WIRING SYSTEM OF SINGLE PHASE LIGHTING CIRCUIT32
2 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 3ndash WIRING SYSTEM OF SINGLE PHASE POWER CIRCUIT33
LESSON 4ndash CONDUIT BENDING AND TRUNKING FABRICATION TECHNIQUE37
LESSON 5 ndashWIRING SYSTEM OF 1 Oslash LIGHTING AND POWER CIRCUIT42
POWER CIRCUITS42
LESSON 6 ndash WIRING SYSTEM OF 3 Oslash DISTRIBUTION BOARD45
LESSON 7 ndash WIRING SYSTEM OF THREE PHASE LIGHTING AND POWER CIRCUIT52
LESSON 8 INSPECTION AND TESTING OF ELECTRICAL INSTALLATION55
CONTINUITY TEST60
Polarity Test64
Earth Electrode Resistance Test67
Earth Electrode Resistance Measurement Method (Figure 86)67
Residual Current Device Test68
LESSON 9 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (DC)74
LESSON 10 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (AC)76
LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE79
LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER83
LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER1
LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER4
LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER8
a Dead circuit test10
b Life circuit test10
LESSON 1610
TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR10
SELF-ASSESSMENT QUESTIONS11
Electricity Supply Act 1990Electricity Regulations 1994MS IEC 603642003 Standard Electrical Installations of BuildingsMS 19362006 Standard Electrical Installations of Buildings ndash Guide To MS IEC 60364 andMS 19792007 Standard Electrical Installation of Buildings ndash Code of Practice
3 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
ELECTRICITY SUPPLY SPECIFICATIONS
Electricity supply for domestic consumers according to MS IEC 60038 standards meets the
following specifications -
i Single phase supply with nominal voltage of 230V range +10 -6
ii Three phase supply with nominal voltage of 400V range +10 -6
iii Permitted frequency is 50Hz + 1
iv Earthing system type (TT System) as in Figure 21 and Figure 22
4 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Legal Requirements
Regulation 11(1) of the Electricity Regulations 1994 states that all wiring or rewiring of an
installation or extension to an existing installation which shall be carried out by an Electrical
Contractor or a Private Wiring Unit have to obtain the approval in writing from a licensee or supply
authority
1 Planning of Electrical Wiring Work
Prior to carrying out wiring work the wiremancontractor should plan and determine the tasks to be
undertaken so that the work carried out is tidy neat and safe to be used The wiremancontractor shall
-i Undertake a site visit
5 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
ii Determine the consumer load requirements
iii Calculate the maximum load demand and
iv Submit the plans drawings and specifications
The planning flow chart for building wiring installations is as shown in Figure 31
11 Site Visit
The purpose of the site visit is to determine -
i Electrical equipment suitable for use
ii Maximum load demand
iii Single or three phase incoming supply
iv Type of wiring and Equipment arrangement
Determining Consumer Load RequirementsWith the aid of the building floor plans the installation requirements such as the proposed load
placement of electrical equipment and installation design plans can be determined
11 Calculating Maximum Load Demand
The estimate of the maximum load demand is for determining the specifications of the wiring
equipment such as the cables and plans
According to clause 311 of MS IEC 60364 Part 1 to determine the maximum demand for each circuit
while ensuring an economic and reliable design within the permitted voltage drop limits Diversity
factors may be taken into account The maximum current demand calculations for each circuit must be
prepared These details will show the current requirements in amperes for each phase and also assist
in determining the cable sizes
Refer to the Third Schedule (Table A and Table B) and Regulation 11(2) of the Electricity Regulations
1994 to estimate the maximum current demand and the diversity factors that may be used for domestic
installations
12 Submission of the Plans Drawings and Specifications Regulation 65 of the Electricity
Regulations 1994 states that the eligibility to submit plans is as follows -
i Wireman with Single Phase Restriction ndash Low voltage single phase up to 60 A
ii Wireman with Three Phase Restriction ndash Low voltage up to 60A
6 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
2 CONTROL AND PROTECTION SYSTEM FOR ELECTRICAL WIRING
7 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
8 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
21 Selection of Control and Protection System for Electrical Wiring
Control and protection of a wiring is a system of separationisolation and switching together with the
protection system which are needed in every domestic wiring installation
22 Isolation and Switching
Examples of isolation and switching are switches power plugs socket outlets and circuit breakers
Their function is to manually connect and break the supply in a particular circuit without interfering
with other circuits
They also aim to prevent the danger of electrical shocks during maintenance testing fault finding and
repair works
23 Protection
This provides protection from dangers caused by electrical currents such as over current earth
leakage current short circuit lightning etc to the wiring system electrical equipment or consumer
The circuit below shows the isolation and protection devices which must be installed in a domestic
electrical wiring system
1 Current Protection
In general protection from the dangers of current can be divided into two aspects namely
i Overcurrent Protection (Over Load or Short Circuit) Properly rated circuit breakers or fuses suitable
for over load or short circuit protection must be used
9 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
The circuit breakers or fuses must be installed on the live conductors only For three phase circuits all
the circuit breakers or fuses must be combined in one set of circuits
Selection of over current devices must be based on the short circuit fault current levels of the circuit
breaker or main switch (kA)
ii Earth Leakage Current Protection
Properly rated Residual Current Devices (RCD) must be used for protection from earth leakage
currents (to prevent electric shocks)
a) Regulation 36(1) of the Electricity Regulations 1994 states that for a place of public entertainment
protection against earth leakage current must be provided by a residual current device of sensitivity
not exceeding 10 mA
b) Regulation 36(2) of the Electricity Regulations 1994 states that for a place where the floor is likely
to be wet or where the wall or enclosure is of low electrical resistance protection against earth leakage
current must be provided by a residual current device of sensitivity not exceeding 10 mA
c) Regulation 36(3) of the Electricity Regulations 1994 states that for an installation where hand-held
equipment apparatus or appliance is likely to be used protection against earth leakage current must be
provided by a residual current device of sensitivity not exceeding 30 mA and
d) Regulation 36(4) of the Electricity Regulations 1994 states that for an installation other than the
installation in (a) (b) and (c) protection against earth leakage current must be provided by a residual
current device of sensitivity not exceeding 100 mA
CABLE SELECTION
31 Selection of Wiring Cable Type
The selection of the cable size has to take into consideration the following-
i All wiring cables must be PVC or PVCPVC insulated with copper conductors Conductors with
cross sectional areas of 16mm2 or less must be of copper Aluminium conductors are not permitted
Refer to Table 4D1A in Appendix II for the current carrying capacities of copper conductor
ii Cables for swimming pools must be water resistant PE (polyethylene) insulated
10 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
iii The selected cable must be capable of delivering the electrical energy efficiently
iv The cable size allows it to carry the current without heating the cable
v The voltage drop must not exceed 4 of the supply voltage Refer to Table 4D1B in Appendix III
vi The cable insulation must be suitable for the surrounding conditions of the installation such as the
ability to withstand the surrounding temperatures and the ability to provide mechanical protection
vii Each conductor in the installation must be protected from overcurrent by means of overcurrent
protection devices needed to prevent damage to the cable insulation
32 Factors Related to Cable Current Carrying CapacityThe following factors in relation to the current carrying capacity of cables must be taken into
consideration-
i Surface wiring using clips ndash group factor
ii Wiring using conduits ndash space factor 40
iii Wiring using ducts ndash space factor 45
iv Concealed wiring ndash group factor and
v Concealed wiring using ducts ndash surrounding temperature factor
Use of Minimum Cross Sectional Area Rating of Wiring ConductorsThe following are the minimum cross sectional areas of conductors based on their applications-
Use of Protection Conductor Minimum Cross Sectional Area Rating
In Comparison with Phase Conductor Cross Sectional Area
The following table shows the protection conductor minimum cross sectional area in comparison
with the phase conductor cross sectional area
Functions and Colour Identification of Non Flexible Cables
The following table shows the functions and colour identification of non flexible cables
11 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
33 Use of Minimum Cross Sectional Area Rating of Wiring Conductors
The following are the minimum cross sectional areas of conductors based on their applications-
34 Use of Protection Conductor Minimum Cross Sectional Area Rating
In Comparison with Phase Conductor Cross Sectional Area
The following table shows the protection conductor minimum cross sectional area in comparison
with the phase conductor cross sectional area
Use of Minimum Cross Sectional Area Rating of Wiring Conductors
The following are the minimum cross sectional areas of conductors based on their applications-
Use of Protection Conductor Minimum Cross Sectional Area Rating
In Comparison with Phase Conductor Cross Sectional Area
The following table shows the protection conductor minimum cross sectional area in comparison
with the phase conductor cross sectional area
Functions and Colour Identification of Non Flexible CablesThe following table shows the functions and colour identification of non flexible cables
12 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Flexible Cables
i Flexible cables of cross sectional area less than 40 mm2 are used in installations for electrical
accessories such as ceiling roses lamp fixtures or attachments socket plugs for mobile
appliances etc
ii Flexible cables shall not be used for permanent wiring
iii Flexible cables for the permanent use of electrical appliances should not exceed 3 meters in
length
37 Functions and Colour Identification of Flexible Cables
Conductor Insulation and Types of WiringVarious material and insulation layers are used for conductor protection Cable selection in
accordance to insulation layers must be done correctly for the type of the wiring installation as
shown in the table below
Functions and Colour Identification of Non Flexible CablesThe following table shows the functions and colour identification of non flexible cables
3 SELECTION OF WIRING ACCESSORIES
i All wiring accessories to be used have to be of those approved by the Energy Commission and
labeled with labels issued by SIRIM For all wiring using UPVC conduits -
13 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
a) Switches socket outlets 3 pin plugs ceiling roses connectors sockets ndash construction material shall
be of polycarbonate type
iii For all wiring using metal conduits - Switches socket outlets and connectors ndash construction
material shall be of metal clad type and All accessories shall be effectively earthed
iv Switch fuse used in single phase installations shall have the fuse permanently connected and not
move with the fuse
v Fuse switch used in 3 phase domestic installations also has fuse and switch The fuse connector is
installed together to allow the fuse to move simultaneously with the switch
vi Lamp
a) Fluorescent lamps using magnetic ballasts (watt loss not exceeding 6 watts) shall be
equipped with dry paper type capacitor
b) Fluorescent lamps using electronic ballasts or high frequency electronic ballasts do not
need capacitors
c) Outdoor domestic lamp installations shall use weather proof and water proof lamps
d) Submerged light installations (example in swimming pools fountains etc) shall have water
proof lamps with a voltage not exceeding 12 Volt AC
vii Electric water heaters is divided into 2 types namely
1 instantaneous water heaters and
2 stored water heaters (storage tank type)
a) Instantaneous water heaters shall be equipped with a 2 pole control switch and its own
residual current device
b) Storage water heaters (storage tank type) shall be installed with an
Water heaters exceeding 3kW shall be permanently connected to a 20A30A rated circuit
breakerfuse with an isolator switch and residual current device
viii Electric cookers exceeding 3kW shall have its own circuit connected permanently to a 30A rated
circuit breaker or fuse with an isolator switch and cooker control unit incorporated with a 13A socket
outlet Two or more cooker appliances may be installed in the same room within a distance of 2
meters
ix Electric motors (fence gate air conditioners fountains swimming pools fish ponds water
pumps) exceeding 373W but not exceeding 2238W shall be connected permanently to a 20A30A
rated circuit breakerfuse together with an isolator motor starter and 15A socket outlet
14 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
The motor starter shall be of Direct-On-Line type with the appliance together with the contactor
overload relay and on-off control The circuit breakerfuse which controls the motor circuit shall be
capable of withstanding the starting current of the motor
x Electric bells ndash the circuit shall have a push button switch and a ACDC transformer
xi Ceiling fans shall conform to clause 21101 of the MS 12192002 standard with regards to test on
the suspension system of ceiling fans
EARTHING OF ELECTRICAL INSTALLATIONS51 Earthing
Earthing is a connection system between the metallic parts of an electrical wiring system and the
general mass of the earth This will provide an easy path with a low impedence or resistance to earth to
enable the protection system to operate effectively It will thus ensure safety to human
beingsconsumers from the dangers of electric shocks if earth leakage currents are present In general
an electrical installation is earthed because of -
i Safety reasons
ii Protection system requirements
iii Need to limit over voltages
iv Need to provide a path for electrical discharge
v Legal requirements
52 Classification of Earthing
Generally earthing can be divided into 2 parts namely -
i System Earthing
a To isolate the system under fault conditions
b To limit the potential difference between conductors which are not insulated in an area
c To limit the occurrence of over voltages under various conditions
ii Equipment Earthing
Equipment earthing is undertaken to protect human beingsconsumers If a live source comes into
contact with the equipment body electrical energy will flow to the earth without flowing through the
human being consumerrsquos body This is because of the fact that the human body has a greater
resistance compared with the resistance to earth
53 Types and Functions of Earthing Accessories
Earthing accessories are as follows -
i Earthing Electrode
Copper jacketed steel core rods are used as electrodes for domestic wiring
ii Equipotential Bonding
15 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
This is the conductor which is connected between the consumer earthing point and the exposed
metallic part The minimum cable size for this purpose is 10 mm2
iii Protection Conductor
This is the conductor which connects the consumer earthing point with other parts of the installation
which needs earthing Its size is as follows-
a) Same size as the phase cable up to a size of 16mm2
b) 16 mm2 if the phase cable size is between 16 mm2 and 35 mm2
c) Half the size of the phase cable if the size of the phase cable exceeds 35 mm2
54 Earthing Arrangements Using a TT System
i The first alphabet indicates the earthing arrangements from the supply side
ii The second alphabet indicates the earthing arrangement in the consumerrsquos installation
T ndash first Indicates that the supply system has its own earthing arrangements
T ndash second Indicates that all metallic frames of the electrical appliances etc are connected directly to
earth
Parts that are Required to be Earthed
i All metallic structures in the wiring system (non current carrying) such as metallic covers conduits
ducts the armour of catenary wires etc
ii A secondary winding point in a transformer and
iii Frame of metal roof truss
56 Parts that are not Required to be Earthed
i Short isolated metallic parts for mechanical protection of cables which have non metallic sheaths
other than conduits which are connected at entry points between the building and conduits which
protect discharge lamp cables
ii Cable clips for installing cables
iii Metallic covers for lamps
16 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
iv Small metallic parts such as screws and name plates which are isolated by means of insulation
v Metallic lamp parts for filament lamps in water proof floors
57 Termination to Earth
The termination to earth is done as shown in Figure 72
Earth Electrode Resistance
The maximum permitted earth electrode resistance for different types of installations is as shown in
the Table below
Earth electrode for installations protected by RCDs of sensitivity 100mA 10 Ω
Lightning arrestor earth electrode 10 Ω
Legal Requirements
i Sub regulation 12(1) and 12(2) of the Electricity Regulations 1994 state that any electrical wiring in
an installation shall be under the immediate supervision of a Wireman with Single Phase Restriction or
Three Phase Restriction Upon completion the Wireman shall certify a Supervision and Completion
Certificate
ii Sub regulation 13(1) and 13 (2) of the Electricity Regulations 1994 state that the installation shall
be tested by a Wireman with Single Phase Restriction or a Wireman with Three Phase Restriction
authorized to test any installation and who shall certify a Test Certificate for the installation
iii Sub regulation 14(1) of the Electricity Regulations 1994 states that the Supervision and
Completion Certificate and the Test Certificate as in regulations 12 and 13 shall be in Forms G and H
respectively as prescribed in the First Schedule
17 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
4 SAFETY REQUIREMENTS FOR ELECTRICAL WIRING WORKS IN RESIDENTIAL BUILDINGS
61 Safety Requirements
Safety requirements for electrical wiring works have to be followed to eliminate any accidents which
can result in physical damage or loss of life or property Failure to meet the safety regulations may
result in workers consumers or the public being inflicted with electrical shocks
In addition to this safety steps will also encourage workers or electricity consumers who are
disciplined and who always give importance to safety
62 Safety Steps
Safety requirements have to be followed whenever electrical works are undertaken in a residential
building
i Personal Safety
a Use suitable personal protection equipment as needed such as safety shoes gloves safety helmet
etc when at the work place
b Use safety clothing suitable for the work to be undertaken
c Do not wear jewellery or decorative items such as rings watches chains etc while carrying out
electrical works
ii Safety at the Work Place
a Acquire knowledge about the dangers of electrical works that is to be undertaken and how to deal
with those dangers
b Always adhere to the safety regulations which have been set for the work place
c Ensure that the electricity supply is switched off before carrying out the works
d Acquire the needed knowledge and practice a cautious and calm attitude while working ensure
cleanliness in and around fellow workers
e While working at elevated places the worker should always use suitable equipment such as wooden
or aluminium ladders iron scaffoldings or platforms safety belts or other equipment needed to ensure
that the work can be undertaken safely
f Use electrical equipment which is operational and safe to be used and ensure that the supply for it is
being supplied through a residual current device (RCD) with a sensitivity of 30 mA
g Ensure that exposed temporary supply electrical cables have mechanical protection
h If inflammable or corrosive material is present necessary safety steps have to be undertaken as
required by the relevant safety regulations
63 Dangers of Electrical Shocks
i Electrical Shock
Electrical shocks can occur due to direct or indirect contact
a Direct Contact
18 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Direct contact occurs when the worker or consumer receives an electrical shock on touching directly a
live conductor or cable
b Indirect Contact
Here the electric shock occurs due to contact with a part which is connected to the electrical
installation and not to a direct contact with a live cable or conductor possibly due to damages in the
appliance or insulation resulting in leakages of current
Why Electric Shocks Occura Unsafe Work Method or Action Undertaking Electrical Work Without Disconnecting the
Supply
Maintenance or circuit testing work done without disconnecting the supply will have a high possibility
of electrical shocks occurring
bull Not Following Safe Work Procedures
To eliminate the occurrence of electrical shocks each worker has to always follow safe work
procedures which are set by regulations and standards
b Defects in the Electrical System
i Leakage Current
Leakage currents or earth leakage currents can result in the metallic frames becoming live and
energised This can give rise to the danger of electrical shock to the worker consumer or the public if
they hold or come into contact with the metallic frame
ii Exposed Conductor or Disconnected Cable
Exposed conductors or cables which are broken and are alive (energised) can result in electrical shock
when touched The supply source must be immediately isolated or switched off and a report must be
made to the responsible entity
64 First Aid and Basic Pulmonary Resuscitation
i First Aid
First aid is the initial assistance given to a person who has met with an accident is sick or is injured to
prevent the condition of the victim from becoming more serious while awaiting the arrival of the
paramedics (ambulance) or before being brought to the hospital
i Pulmonary Resuscitation
Pulmonary resuscitation has to be undertaken to assist the victim who has breathing difficulties as a
result of being drowned receiving an electrical shock etc Pulmonary resuscitation has to be carried
out in accordance to the correct method as stated in the first aid manuals issued by accredited first aid
bodies
ii First Aid Box
19 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
A first aid box has to be provided by the building owner construction site supervisor or brought
personally by the worker under the supervision of the responsible person
65 Training Programme
The management shall conduct periodic training programmes for the workers with regards to work
safety on aspects including the following -
i Dangers of electrical work being undertaken and how to control those dangers
ii The safety regulations set for the work place and
iii First aid procedures
66 Fire Prevention
Fire Extinguisher A suitable functioning fire extinguisher to control fires has to be made available at
the work place at all times
67 Competent Person
The Electricity Regulations 1994 require that all electrical work has to be undertaken by or under the
direct supervision of a competent person registered with the Energy Commission Besides that the
electrical contractor undertaking the electrical work has also to be registered with the Energy
Commission The installation owner thus has to ensure that the appointed electrical contractor is
registered with the Energy Commission and that the registration is still valid
INSTALLATION CIRCUITS AND SYSTEMS1 Block diagrams
These show using squares rectangles etc the sequence of a system without too much technical detail
eg Figures 1517 and 1526
2 Layout diagrams
These are very similar to block diagrams but they indicate more technical detail and tend to show
items in their correct geographical location (eg Figures 1518 and 1519)
3 Circuitschematic
These show how a circuit functions and takes no account of exact locations of terminals or equipment
(eg Figures 1528 1529 1532 1534 etc)
4 Wiring diagram
These indicate how a circuit or system is physically wired (eg Figures 152 154 156 etc)
Most induction motors are started directly on line but when very large motors are started that way
they cause a disturbance of voltage on the supply lines due to large starting current surges To limit the
starting current surge large induction motors are started at reduced voltage and then have full supply
voltage reconnected when they run up to near rotated speed Two methods are used for reduction of
starting voltage are star delta starting and auto transformer stating
20 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Working Principal of Star-Delta Starter
This is the reduced voltage starting method Voltage reduction during star-delta starting is achieved by
physically reconfiguring the motor windings as illustrated in the figure below During starting the
motor windings are connected in star configuration and this reduces the voltage across each winding 3
This also reduces the torque by a factor of three After a period of time the winding are reconfigured as
delta and the motor runs normally
StarDelta starters are probably the most common reduced voltage starters They are used in
an attempt to reduce the start current applied to the motor during start as a means of reducing the
disturbances and interference on the electrical supply
Traditionally in many supply regions there has been a requirement to fit a reduced voltage
starter on all motors greater than 5HP (4KW) The StarDelta (or WyeDelta) starter is one of the
lowest cost electromechanical reduced voltage starters that can be applied
The StarDelta starter is manufactured from three contactors a timer and a thermal overload
The contactors are smaller than the single contactor used in a Direct on Line starter as they are
controlling winding currents only The currents through the winding are 1root 3 (58) of the
current in the line
There are two contactors that are close during run often referred to as the main contractor and
the delta contactor These are AC3 rated at 58 of the current rating of the motor The third
contactor is the star contactor and that only carries star current while the motor is connected in star
The current in star is one third of the current in delta so this contactor can be AC3 rated at one
third (33) of the motor rating
Star-delta Starter Consists following units
1) Contactors (Main star and delta contactors) 3 Norsquos (For Open State Starter) or 4 Norsquos (Close
Transient Starter)
2) Time relay (pull-in delayed) 1 No
3) Three-pole thermal over current release 1No
4) Fuse elements or automatic cut-outs for the main circuit 3 Nos
5) Fuse element or automatic cut-out for the control circuit 1No
Power Circuit of Star Delta Starter
1 The main circuit breaker serves as the main power supply switch that supplies electricity to the
power circuit
2 The main contactor connects the reference source voltage R Y B to the primary terminal of the
motor U1 V1 W1
21 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
3 In operation the Main Contactor (KM3) and the Star Contactor (KM1) are closed initially and
then after a period of time the star contactor is opened and then the delta contactor (KM2) is
closed The control of the contactors is by the timer (K1T) built into the starter The Star and Delta
are electrically interlocked and preferably mechanically interlocked as well In effect there are
four states
4 The star contactor serves to initially short the secondary terminal of the motor U2 V2 W2 for the
start sequence during the initial run of the motor from standstill This provides one third of DOL
current to the motor thus reducing the high inrush current inherent with large capacity motors at
startup
5 Controlling the interchanging star connection and delta connection of an AC induction motor is
achieved by means of a star delta or wye delta control circuit The control circuit consists of push
button switches auxiliary contacts and a timer
Control Circuit of Star-Delta Starter (Open Transition)
1 The ON push button starts the circuit by initially energizing Star Contactor Coil (KM1) of star
circuit and Timer Coil (KT) circuit
2 When Star Contactor Coil (KM1) energized Star Main and Auxiliary contactor change its
position from NO to NC
3 When Star Auxiliary Contactor (1)( which is placed on Main Contactor coil circuit )became
NO to NC itrsquos complete The Circuit of Main contactor Coil (KM3) so Main Contactor Coil
energized and Main Contactorrsquos Main and Auxiliary Contactor Change its Position from NO
To NC This sequence happens in a friction of time
4 After pushing the ON push button switch the auxiliary contact of the main contactor coil (2)
which is connected in parallel across the ON push button will become NO to NC thereby
providing a latch to hold the main contactor coil activated which eventually maintains the
control circuit active even after releasing the ON push button switch
5 When Star Main Contactor (KM1) close its connect Motor connects on STAR and itrsquos
connected in STAR until Time Delay Auxiliary contact KT (3) become NC to NO
6 Once the time delay is reached its specified Time the timerrsquos auxiliary contacts (KT)(3) in
Star Coil circuit will change its position from NC to NO and at the Same Time Auxiliary
contactor (KT) in Delta Coil Circuit(4) change its Position from NO To NC so Delta coil
energized and Delta Main Contactor becomes NO To NC Now Motor terminal connection
change from star to delta connection
7 A normally close auxiliary contact from both star and delta contactors (5amp6)are also placed
opposite of both star and delta contactor coils these interlock contacts serves as safety
switches to prevent simultaneous activation of both star and delta contactor coils so that one
22 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
cannot be activated without the other deactivated first Thus the delta contactor coil cannot be
active when the star contactor coil is active and similarly the star contactor coil cannot also
be active while the delta contactor coil is active
8 The control circuit above also provides two interrupting contacts to shutdown the motor
The OFF push button switch break the control circuit and the motor when necessary The
thermal overload contact is a protective device which automatically opens the STOP Control
circuit in case when motor overload current is detected by the thermal overload relay this is to
prevent burning of the motor in case of excessive load beyond the rated capacity of the motor
is detected by the thermal overload relay
9 At some point during starting it is necessary to change from a star connected winding to a
delta connected winding Power and control circuits can be arranged to this in one of two
ways ndash open transition or closed transition
What is Open or Closed Transition Starting
(1) Open Transition Starters
Discuss mention above is called open transition switching because there is an open state between
the star state and the delta state
In open transition the power is disconnected from the motor while the winding are reconfigured via
external switching
When a motor is driven by the supply either at full speed or at part speed there is a rotating
magnetic field in the stator This field is rotating at line frequency The flux from the stator field
induces a current in the rotor and this in turn results in a rotor magnetic field
When the motor is disconnected from the supply (open transition) there is a spinning rotor within
the stator and the rotor has a magnetic field Due to the low impedance of the rotor circuit the time
constant is quite long and the action of the spinning rotor field within the stator is that of a
generator which generates voltage at a frequency determined by the speed of the rotor When the
motor is reconnected to the supply it is reclosing onto an unsynchronized generator and this result
in a very high current and torque transient The magnitude of the transient is dependent on the
phase relationship between the generated voltage and the line voltage at the point of closure can
be much higher than DOL current and torque and can result in electrical and mechanical damage
Open transition starting is the easiest to implement in terms or cost and circuitry and if the timing
of the changeover is good this method can work well In practice though it is difficult to set the
necessary timing to operate correctly and disconnectionreconnection of the supply can cause
significant voltagecurrent transients
In Open transition there are Four states
23 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 OFF State All Contactors are open
2 Star State The Main [KM3] and the Star [KM1] contactors are closed and the delta [KM2]
contactor is open The motor is connected in star and will produce one third of DOL torque at one
third of DOL current
3 Open State This type of operation is called open transition switching because there is an
open state between the star state and the delta state The Main contractor is closed and the Delta
and Star contactors are open There is voltage on one end of the motor windings but the other end
is open so no current can flow The motor has a spinning rotor and behaves like a generator
4 Delta State The Main and the Delta contactors are closed The Star contactor is open The
motor is connected to full line voltage and full power and torque are available
(2) Closed Transition StarDelta Starter
There is a technique to reduce the magnitude of the switching transients This requires the use of a
fourth contactor and a set of three resistors The resistors must be sized such that considerable
current is able to flow in the motor windings while they are in circuit
The auxiliary contactor and resistors are connected across the delta contactor In operation just
before the star contactor opens the auxiliary contactor closes resulting in current flow via the
resistors into the star connection Once the star contactor opens current is able to flow round
through the motor windings to the supply via the resistors These resistors are then shorted by the
delta contactor If the resistance of the resistors is too high they will not swamp the voltage
generated by the motor and will serve no purpose
In closed transition the power is maintained to the motor at all time This is achieved by
introducing resistors to take up the current flow during the winding changeover A fourth
contractor is required to place the resistor in circuit before opening the star contactor and then
removing the resistors once the delta contactor is closed These resistors need to be sized to carry
the motor current In addition to requiring more switching devices the control circuit is more
complicated due to the need to carry out resistor switching
In Close transition there are Four states
1 OFF State All Contactors are open
2 Star State The Main [KM3] and the Star [KM1] contactors are closed and the delta [KM2]
contactor is open The motor is connected in star and will produce one third of DOL torque at one
third of DOL current
Star Transition State The motor is connected in star and the resistors are connected across the
delta contactor via the aux [KM4] contactor
24 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Closed Transition State The Main [KM3] contactor is closed and the Delta [KM2] and Star
[KM1] contactors are open Current flows through the motor windings and the transition resistors
via KM4
Delta State The Main and the Delta contactors are closed The transition resistors are shorted out
The Star contactor is open The motor is connected to full line voltage and full power and torque
are available
Effect of Transient in Starter (Open Transient starter)
It is Important the pause between star contactor switch off and Delta contactor switch is on correct
This is because Star contactor must be reliably disconnected before Delta contactor is activated It
is also important that the switch over pause is not too long
For 415v Star Connection voltage is effectively reduced to 58 or 240v The equivalent of 33
that is obtained with Direct Online (DOL) starting
If Star connection has sufficient torque to run up to 75 or 80 of full load speed then the motor
can be connected in Delta mode
When connected to Delta configuration the phase voltage increases by a ratio of V3 or 173 The
phase currents increase by the same ratio The line current increases three times its value in star
connection
During transition period of switchover the motor must be free running with little deceleration
While this is happening ldquoCoastingrdquo it may generate a voltage of its own and on connection to the
supply this voltage can randomly add to or subtract from the applied line voltage This is known as
transient current Only lasting a few milliseconds it causes voltage surges and spikes Known as
a changeover transient
Size of each part of Star-Delta starter
(1) Size of Over Load Relay
For a star-delta starter there is a possibility to place the overload protection in two positions in the
line or in the windings
Overload Relay in Line
In the line is the same as just putting the overload before the motor as with a DOL starter
The rating of Overload (In Line) = FLC of Motor
Disadvantage If the overload is set to FLC then it is not protecting the motor while it is in delta
(setting is x1732 too high)
Overload Relay in Winding
25 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
In the windings means that the overload is placed after the point where the wiring to the contactors
are split into main and delta The overload then always measures the current inside the windings
The setting of Overload Relay (In Winding) =058 X FLC (line current)
Disadvantage We must use separate short circuit and overload protections
(2) Size of Main and Delta Contractor
1 There are two contactors that are close during run often referred to as the main contractor and
the delta contactor These are AC3 rated at 58 of the current rating of the motor
Size of Main Contactor= IFL x 058
(3) Size of Star Contractor
The third contactor is the star contactor and that only carries star current while the motor is
connected in star The current in star is 1 radic3= (58) of the current in delta so this contactor can
be AC3 rated at one third (33) of the motor rating
Size of Star Contactor= IFL x 033
Motor Starting Characteristics of Star-Delta Starter
Available starting current 33 Full Load Current
Peak starting current 13 to 26 Full Load Current
Peak starting torque 33 Full Load Torque
Advantages of Star-Delta starter
The operation of the star-delta method is simple and rugged
It is relatively cheap compared to other reduced voltage methods
Good TorqueCurrent Performance
It draws 2 times starting current of the full load ampere of the motor connected
Disadvantages of Star-Delta starter
Low Starting Torque (Torque = (Square of Voltage) is also reduce)
Break In Supply ndash Possible Transients
Six Terminal Motor Required (Delta Connected)
It requires 2 set of cables from starter to motor
It provides only 33 starting torque and if the load connected to the subject motor requires higher
starting torque at the time of starting than very heavy transients and stresses are produced while
changing from star to delta connections and because of these transients and stresses many
electrical and mechanical break-down occurs
26 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
In this method of starting initially motor is connected in star and then after change over the motor
is connected in delta The delta of motor is formed in starter and not on motor terminals
High transmission and current peaks When starting up pumps and fans for example the load
torque is low at the beginning of the start and increases with the square of the speed When
reaching approx 80-85 of the motor rated speed the load torque is equal to the motor torque and
the acceleration ceases To reach the rated speed a switch over to delta position is necessary and
this will very often result in high transmission and current peaks In some cases the current peak
can reach a value that is even bigger than for a DOL start
Applications with a load torque higher than 50 of the motor rated torque will not be able to start
using the start-delta starter
Low Starting Torque The star-delta (wye-delta) starting method controls whether the lead
connections from the motor are configured in a star or delta electrical connection The initial
connection should be in the star pattern that results in a reduction of the line voltage by a factor of
1radic3 (577) to the motor and the current is reduced to 13 of the current at full voltage but the
starting torque is also reduced 13 to 15 of the DOL starting torque
The transition from star to delta transition usually occurs once nominal speed is reached but is
sometimes performed as low as 50 of nominal speed which make transient Sparks
Features of star-delta starting
1 For low- to high-power three-phase motors
2 Reduced starting current
3 Six connection cables
4 Reduced starting torque
5 Current peak on changeover from star to delta
6 Mechanical load on changeover from star to delta
Application of Star-Delta Starter
The star-delta method is usually only applied to low to medium voltage and light starting
Torque motors
The received starting current is about 30 of the starting current during direct on line start and the
starting torque is reduced to about 25 of the torque available at a DOL start This starting
method only works when the application is light loaded during the start If the motor is too heavily
27 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
loaded there will not be enough torque to accelerate the motor up to speed before switching over
to the delta position
LESSON 1 WIRING SYSTEM OF SINGLE PHASE DISTRIBUTION BOARD
Introduction
28 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
29 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
30 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
31 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 2 WIRING SYSTEM OF SINGLE PHASE LIGHTING CIRCUIT Introduction
Objectives
1 Identify component and the specification
2 Wire component according to the schematic diagram
3 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Wiring bay Perforated metal 180 cm x 180 cm 1
2 Cut out fuse 63 A 240 V 1
3 Neutral link 1
4 Single pole one way switch cw
switch box
5A 240Vac 4
5 single pole two way switch cw
switch box
5A 240Vac 2
6 RCCB In = 40 A Tripping current
100mA240 Vac 50 Hz
1
7 Main switch 32 A 240V 1
8 kWatthour meter 40 A 240 Vac 1
9 Single pole MCB 6A 240 Vac 1
10 Self tapping Wood screw As required
11 DIN rail 35 mm width As required
32 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
12 PVC trunking 50 mm x 50 mm As required
13 Terminal blocks 5 A As required
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
1 One way switch to control one lamp
2 One way switch to control two lamps
3 Two of two way switch to control one lamp
4 Two of single pole two way switch and one of an intermediate switch to control one
lamp
5 One unit of ceiling fan and fan regulator to be controlled by one way switch
4 Test the functionality of completed project
LESSON 3ndash WIRING SYSTEM OF SINGLE PHASE POWER CIRCUIT Introduction
33 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
34 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify types of component and its specification
2 Wire component according to the schematic diagram given
3 Test the functionality of the circuit dead circuit test life circuit test
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board Perforated Metal 1
2 kWh meter 240 V 40 A 1
3 Socket outlet 13A 240Vac 4
4 RCCB 40A Trip Amps
30mA240 Vac
1
5 3 pin socket 240Vac 13A 4
6 Single pole MCB 20A 240 V 2
7 DOL starter 1 kW 240Vac 2
8 1 phase induction motor 2Hp 240 Vac 1
9 Cooker control unit 4kW 240Vac 1
10 Water heater point 4kW 240 Vac 1
11 DIN rail 35 mm As required
12 PVC casing 20mm As required
13 Flexible wires 05 mm As required
14 Terminal block 10 A As required
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Wire two unit of 13 A socket outlet in radial circuit
3 Wire four units of 13 A socket outlet in ring circuit
4 Wire one unit DOL starter for air-conditioner point
5 Wire one unit of cooker control unit point
6 Wire one unit of water heater point
7 Test the functionality of each component by using mmeter or power supply whichever
applicable
8 Wire component according to circuit diagram
9 Test the functionality of completed project dead circuit test life circuit test
Note
35 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Ensure that the correct rating of protection device and size of wire used
LESSON 4ndash CONDUIT BENDING AND TRUNKING FABRICATION TECHNIQUE
Common fitting used in an industrial wiring
Cutting and threading the condute
36 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
37 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
38 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify conduit fitting and the specification
2 Measure and Cut steel conduit according to specified dimension
3 Bend and fabricate conduit at 45 90 according to layout diagram
4 Wire component according to the schematic diagram
5 Test the functionality of the circuit
39 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Conduit Bender Oslash 19 mm ( frac34 ldquo) 1
2 Measuring Tape 3 metre 1
3 Hacksaw frame and blade 30cm 1
4 Conduit cutter 1
5 Pipe Vise 1
6 Pipe Wrench 1
7 Ratchet Dies 20 mm 1
8 Metal trunking 50 mm x 50 mm 1
9 GI conduit 20mm 1
10 End box 20 mm 1
11 Flexible wires 05 mm As required
12 Connectors 5 A As required
13 Single core PVC ins Cable 25 mm 2 As required
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Wire two unit of 13 A socket outlet in radial circuit
3 Wire four unit of 13 A socket outlet in ring circuit
4 Wire one unit DOL starter for air-conditioner point
5 Wire one unit of cooker control unit point
6 Wire one unit of water heater point
7 Test the functionality of each component by using multimeter or power supply whichever
applicable
8 Wire component according to circuit diagram
9 Test the functionality of completed project
Note
Ensure that the rating of protection device and size of wire
K prior to 31 March
2004 (BS 7671)
(formerly)
bare conductor
sleeved at terminations (formerly)
40 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 5 ndashWIRING SYSTEM OF 1 Oslash LIGHTING AND POWER CIRCUIT
POWER CIRCUITSa Radial circuits
Radial circuits are arranged in the same way as item 1 above in lighting layouts in that each socket
outlet is supplied via the previous one
Points to note
1 The number of socket outlets complying with BS 1363 is unlimited for a floor area of up to 50m 2 if
the circuit protection is a 30 A or 32 A cartridge fuse or circuit breaker the cable being 4 mm PVC
copper or 25 mm2 mineral insulated (mi)
2 The number of socket outlets is unlimited for a floor area up to 20 m 2 with any type of circuit
protection of 20 A using 25 mm2 PVC copper cable or 15 mm2 mi
3 The total number of fused spurs is unlimited
b ring final circuits
These circuits are the same as radial circuits except that the final socket outlet is wired back to the
supply position In effect any outlet is supplied from two directions (Fig 152)
Points to note
1 Every twin-socket outlet counts as two single-socket outlets
2 The number of non-fused spurs must not exceed the total number of points on the ring Fig 158
shows seven points on the ring and five spurs
3 The fuse rating of a fused spur box must not exceed 13 A and the current rating of all points supplied
by the fused spur must not exceed 13 A
4 Non-fused spurs must supply no more than one single or one double socket on the ring Fig 158
shows seven points on the ring and five spurs rating of all points supplied by the fused spur must not
exceed 13 A or one stationary appliance
CapacityMain conductor size
copper (mm2)
Earth conductor
size (mm2)
Circuit breaker
capacity (A)
Up to 600 W 15 15 6
600ndash1200 W 1525 15 10
1200ndash1800 W 254 25 16
41 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Ring circuit
(floor area 100 m2)25 15 3032
A2 radial circuit
(floor area 75 m2)40 25 3032
A3 radial circuit
(floor area 50 m2)25 15 20
Air conditioner (15 tonne) 60 60 3032
Cooker 60 60 3032
Water heater 40 40 20
Objectives
1 Identify component and the specification
2 Wire component according to the schematic diagram
3 Test the functionality of the circuit
42 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board Perforated 1
2 Cut out fuse and neutral link 60A 240V 1each
3 kWh meter 240V 40A 1
4 Switched Socket outlet 13A 240Vac 4
5 Single pole two way switch cw switch
box
5A 240Vac 2
6 RCCB ELCB 63 A Tripping current 100mA
415 Vac
1
7 3 pin plug 240Vac 13A 4
8 Single pole MCB 20 A 2
9 Single pole MCB 6A 1
10 Single pole MCB 20A 2
11 DOL starter 240Vac 2
12 1 phase induction motor 2hp 240 Vac 1
13 Self tapping Wood screw As required
14 DIN rail Stainless steel allum35 mm As required
15 PVC pipe 20mm dia As required
16 End box 20 mm dia 4
17 Flexible wires 05 mm 2 As required
18 Connectors 5 A As required
Procedures
43 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
4 Test the functionality of completed project
LESSON 6 ndash WIRING SYSTEM OF 3 Oslash DISTRIBUTION BOARD
Introduction
44 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
45 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
46 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
47 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
48 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify each component and the specification
2 Wire component according to the schematic diagram given
3 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting Board 450 x 600 mm Perforated metal 1
2 5 pin round socket and plug 415V ac 32A 1
3 Cut out fuse 60 A 3
4 Neutral link 1
5 kWatt hour meter 415V 60A 1
6 ELCB RCCB 3P+N In=63A415 Vac I trip= 300mA 1
7 ELCB RCCB 3P+N In=63A415 Vac I trip= 30mA 1
8 Single pole MCB 6A 240 V 3
9 Single pole MCB 20A 240 V 3
10 DOL starter 20 A 240Vac 2
11 Socket outlet 15 A 240 Vac 1
12 Switched Socket outlet 13 A 240 Vac 3
13 Led indicating light 5A 240 Vac 3
14 Single pole 4 gang 1 way switch 5A 240 Vac 2
15 Single pole 2 way switch 5A 240 Vac 2
16 1 phase induction motor 1 kW 240Vac 1
17 Metal trunking 30 mm x30 mm As required
18 Self tapping Wood screw 4 mm x 20 mm As required
19 DIN rail 25 mm x 1mm
20 GI steel rigid conduit 20mm As required
21 Flexible conduit 20mm As required
22 End box 20 mm 4
23 Flexible wires 05 mm 2 As required
24 Single core PVC insulated wire 15 mm 2 As required
25 Single core PVC insulated wires 25 mm 2 As required
26 Terminal block 10 A As required
Procedures
49 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify each components and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
4 Test the functionality of completed project
1 dead circuit test
2 life circuit
Note Proper earthing should be made
50 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 7 ndash WIRING SYSTEM OF THREE PHASE LIGHTING AND POWER CIRCUIT
51 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
52 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify component and the specification
2 Wire component according to the schematic diagram
3 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting bay Board Perforated metal 180 cm x 180 cm 1
2 k Watt hour meter 415V 60A 1
3 MCCB 415V 60A
4 ELCB RCCB In=60A415 Vac I trip=30mA 1
5 5 pin round Socket and
plug
415Vac 32A 4
6 Single pole MCB 6A 1
7 Triple pole MCB 20A 2
8 Triple pole Main switch 60A 1
9 DOL starter 240Vac 2
10 3 phase induction motor 2hp 415 Vac 1
11 1 phase induction motor 1
12 Metal trunking 30 mm x30 mm As required
13 Self tapping Wood screw 4 mm x 20 mm As required
14 DIN rail 25 mm x 1mm
15 GI steel rigid conduit 20mm As required
16 Flexible conduit 20mm As required
17 End box 20 mm 4
18 Flexible wires 05 mm As required
19 Connectors 10 A As required
Procedures
1 Identify each components and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
4 Test the functionality of completed project
1 dead circuit 2 life circuit test
5 Record the current drawn by the load as connected in star and delta
Note Proper earthing should be made
53 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 8 INSPECTION AND TESTING OF ELECTRICAL INSTALLATION
On completion of a wiring installation a number of tests on the installation have to be conducted to
ascertain that the wiring circuits and connected appliances are safe for use Prior to carrying out the
tests an inspection has to be done The results of the inspectionsupervision and test have to be
presented in Form G (as in Appendix IV) and Form H (as in Appendix V)
To have the test certification as in Form H the following tests shall be conducted
i Continuity Test
ii Insulation Resistance Test
iii Polarity Test
iv Earth Electrode Resistance test and
v Residual Current Device Test
1 Continuity Test
There are 3 main types of continuity tests for the final circuits-
i Protection Conductor Continuity Test
ii Final Ring Circuit Conductor Continuity Test
iii Live and Neutral Conductor Continuity Test
a) Protection Conductor Continuity Test
bull To ascertain that all protection conductors are connected in the correct and effective manner
bull Test equipment ndash Multimeter (Ohm range) or Ohm meter
54 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
bull Test Method
1 1048766 Ensure that the main switch RCD and MCB are open circuited (switched off) and all loads
are disconnected
2 1048766 Connected the test leads as in the Figure 81 The meter reading shall be less than 1 Ω
55 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Final Ring Circuit Conductor Continuity Test
bull To ensure that all conductors around the ring circuit have continuity
bull Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
bull Test Method
1 1048766 Disconnect both the supply source live conductors from the MCB the neutral conductor
from the neutral terminals and the earth conductor from the earth terminal in the distribution
fuse box
2 1048766 Connect the test leads as in the Figure 82 (EE)
3 1048766 Repeat the procedure for (L-L) and (N-N)
4 1048766 The meter reading value shall be less than 1 ohm
56 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Live and Neutral Conductor Continuity Test
a To ensure that each conductor in the circuit has continuity
b Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
2 Test Method
1 1048766 Switch off the Main switch RCD and MCB
2 1048766 Disconnect all loads
3 1048766 Switch on all switches in the circuit
4 1048766 Disconnect the fusesfinal circuit breakers and close the circuit
5 1048766 Carry out the test as shown in Figure 83
6 1048766 The meter reading value shall be less than 1Ω
57 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
58 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
CONTINUITY TEST
Insulation Resistance Test
i Ensure that there is no leakage current between phase conductors phase and neutral conductors and
phase conductor and earth
ii Test the strength of the cable insulation
iii Test Equipment ndash Insulation Resistance Tester operating voltage is 250VDC or 500VDC
iv Test Method
1 1048766 Switch off main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
59 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
4 1048766 Carry out test as in the Table below
5 1048766 Meter reading value shall be less than 1 Megaohm
60 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
61 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Insulation resitance test
62 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
INSULATION RESISTANCE TEST BETWEEN CONDUCTORS AND OPPOSITE POLARITY
Polarity Testi Ensure that each fuse or single pole control and protection device is connected only in the phase
conductor
ii Intermediate contact of Edison screw lamp holder is connected to the phase conductor
iii Ensure that phase neutral and earth conductors at socket outlets are connected at the correct
terminals
iv Test Equipment ndash Multimeter (Ohm range) or Ohm meter
v Test Method
1 1048766 Switch off Main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in Figure 85
63 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
5 1048766 Test switches and single phase control devices at the phase conductors
6 1048766 Test socket outlet connection sources
7 1048766 Test Edison screw lamp holder connections
8 1048766 Meter reading value shall be less than 1 Ω
64 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Polarity test
65 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Earth Electrode Resistance Testi To test the earth electrode resistance
ii To ascertain the suitability of the location of the electrode
iii To ensure that the electrode is not buried within the resistance area of another electrode
iv Test equipment ndash Earth Resistance Tester
v Test method -
1 1048766 Terminal rsquoErsquo is connected to the electrode to be tested (green conductor)
2 1048766 Terminal lsquoPrsquo is connected to the potential spike (yellow conductor) at a distance of 10
meters from the earth electrode
3 1048766 Terminal lsquoCrsquo is connected to the current spike (red conductor) at a distance of 20 meters
from the earth electrode
Earth Electrode Resistance Measurement Method (Figure 86)
This test must be repeated at least three times to ensure that the reading is not affected by interacting
earthing regions
i Record the first reading (Z1) Example Z1 = 10 Ω
ii Move the voltage spike to a distance of 6 meters from the original position Record the second
reading (Z2 ) Example Z2 = 10 Ω
iii Move the voltage spike to a distance of 6 meters from the original position Record the third
reading (Z3) Example Z3 = 10 Ω
66 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Residual Current Device Testi Ensure that the residual current device (RCD) trips within the set time on the occurrence of current
leakage to earth
ii Test Equipment ndash RCD Tester RCCB Tester
iii Test Method 1
1 1048766 Use the Trip Test Button
2 1048766 Press the trip button found on the RCD to determine if it trips or otherwise This test would
not be able to determine the sensitivity of the RCD nor the time taken for it to trip
iv Test Method 2
i 1048766 Use a RCD Tester
ii This equipment is equipped with a 13A plug which can be connected to a 13A socket outlet
Select the RCD sensitivity to be the same as the sensitivity of the RCD to be tested to
determine if the RCD can trip The time to trip shall not exceed 40 mS
iii 1048766 Test method ndash
a) Position the selection switch in accordance with the sensitivity of the RCD used
Example 100 mA 01 A
b) Position the operations switch to lsquoNo Triprsquo (frac12 Rated mA = 50) connect the 3 pin plug to
the 13A socket outlet
67 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
c) Switch on the 13A socket outlet ndash ensure that the P-N and P-E lights light up
This shows that the polarity is correct (Note if both the lights as above do not light up the test cannot
be continued)
d) Press the test button ndash the reading shows less than 200 mS and simultaneously the lsquotestrsquo light lights
up and the P-N and P-E lights do not light up At that instant the RCD will not trip
e) Move the selection switch to 180o (+ve wave) ndash repeat steps (d) and (e) Move the operations
switch to lsquoTriprsquo (Rated mA = 100)
g) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200mS
h) Move the selection switch to 0o (-ve wave)
i) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
j) The above test is repeated until a near correct reading is obtained
k) Record the test results
l) Change the operations switch to lsquoFast Triprsquo and press the test button ndash RCD will trip within a
time not exceeding 40 millisecond
m) Repeat a number of times at 0o or 180o
On completion of a wiring installation a number of tests on the installation have to be conducted to
ascertain that the wiring circuits and connected appliances are safe for use Prior to carrying out the
tests an inspection has to be done the following tests shall be conducted
i Continuity Test
ii Insulation Resistance Test
iii Polarity Test
iv Earth Electrode Resistance test and
v Residual Current Device Test
821 Continuity Test
There are 3 main types of continuity tests for the final circuits-
i Protection Conductor Continuity Test
ii Final Ring Circuit Conductor Continuity Test
68 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
iii Live and Neutral Conductor Continuity Test
a) Protection Conductor Continuity Test
bull To ascertain that all protection conductors are connected in the correct and effective manner
bull Test equipment ndash Multimeter (Ohm range) or Ohm meter
bull Test Method
1 1048766 Ensure that the main switch RCD and MCB are open circuited (switched off) and all loads are
disconnected
2 1048766 Connected the test leads as in the Figure 81
3 1048766 The meter reading shall be less than 1 Ω
Final Ring Circuit Conductor Continuity Test
bull To ensure that all conductors around the ring circuit have continuity
bull Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
bull Test Method
1 1048766 Disconnect both the supply source live conductors from the MCB the neutral conductor
from the neutral terminals and the earth conductor from the earth terminal in the distribution
fuse box
2 1048766 Connect the test leads as in the Figure 82 (EE)
3 1048766 Repeat the procedure for (L-L) and (N-N)
4 1048766 The meter reading value shall be less than 1 ohm Figure 82 - Final Ring Circuit Conductor
Continuity Test Ohm Meter
Disconnect both the supply source cables from mcbfuse
Take readings at earth conductors of both sources and note resistance readings
Live and Neutral Conductor Continuity Test
1 To ensure that each conductor in the circuit has continuity
2 Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
3 Test Method
1 1048766 Switch off the Main switch RCD and MCB
2 1048766 Disconnect all loads
3 1048766 Switch on all switches in the circuit
4 1048766 Disconnect the fusesfinal circuit breakers and close the circuit
5 1048766 Carry out the test as shown in Figure 83
6 1048766 The meter reading value shall be less than 1 ohm Figure 83 - Live and Neutral
Conductor Continuity Test Ohm Meter
Insulation Resistance Test
69 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
i Ensure that there is no leakage current between phase conductors phase and neutral conductors and
phase conductor and earth
ii Test the strength of the cable insulation
iii Test Equipment ndash Insulation Resistance Tester Operating voltage is 250VDC or 500VDC
iv Test Method
1 1048766 Switch off main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in the Table below
5 1048766 Meter reading value shall be less than 1 Megaohm
Polarity Test
i Ensure that each fuse or single pole control and protection device is connected only in the phase
conductor
ii Intermediate contact of Edison screw lamp holder is connected to the phase conductor
iii Ensure that phase neutral and earth conductors at socket outlets are connected at the correct
terminals
iv Test Equipment ndash Multimeter (Ohm range) or Ohm meter
v Test Method
1 1048766 Switch off Main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in Figure 85
5 1048766 Test switches and single phase control devices at the phase conductors
6 1048766 Test socket outlet connection sources
7 1048766 Test Edison screw lamp holder connections
8 1048766 Meter reading value shall be less than 1 Ω
Earth Electrode Resistance Test
i To test the earth electrode resistance
70 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
ii To ascertain the suitability of the location of the electrode
iii To ensure that the electrode is not buried within the resistance area of another electrode
iv Test equipment ndash Earth Resistance Tester
v Test method -
1 1048766 Terminal rsquoErsquo is connected to the electrode to be tested (green conductor)
2 1048766 Terminal lsquoPrsquo is connected to the potential spike (yellow conductor) at a distance of 10
meters from the earth electrode
3 1048766 Terminal lsquoCrsquo is connected to the current spike (red conductor) at a distance of 20 meters
from the earth electrode E P C Electrode 10 meter 10 meter
Figure 86 ndash Earth Electrode Resistance Measurement Test Equipment
Earth Electrode Resistance Measurement Method (Figure 86)
This test must be repeated at least three times to ensure that the reading is not affected by interacting
earthing regions
i Record the first reading (Z1) Example Z1 = 10 Ω
ii Move the voltage spike to a distance of 6 meters from the original position Record the second
reading (Z2) Example Z2 = 10 Ω
iii Move the voltage spike to a distance of 6 meters from the original position Record the third
reading (Z3)
Example Z3 = 10 Ω
Residual Current Device Test
71 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
i Ensure that the residual current device (RCD) trips within the set time on the occurrence of current
leakage to earth
ii Test Equipment ndash RCD Tester RCCB Tester
iii Test Method 1
1 1048766 Use the Trip Test Button
2 1048766 Press the trip button found on the RCD to determine if it trips or otherwise This test would
not be able to determine the sensitivity of the RCD nor the time taken for it to trip
iv Test Method 2
1048766 Use a RCD Tester
This equipment is equipped with a 13A plug which can be connected to a 13A socket outlet Select the
RCD sensitivity to be the same as the sensitivity of the RCD to be tested to determine if the RCD can
trip The time to trip shall not exceed 40 mS
1048766 Test method ndash
a) Position the selection switch in accordance with the sensitivity of the RCD used
Example 100 mA 01 A
b) Position the operations switch to lsquoNo Triprsquo (frac12 Rated mA = 50) connect the 3 pin plug to
the 13A socket outlet
c) Switch on the 13A socket outlet ndash ensure that the P-N and P-E lights light up This shows that
the polarity is correct (Note if both the lights as above do not light up the test cannot be
continued)
d) Press the test button ndash the reading shows less than 200 millisecond and simultaneously the
lsquotestrsquo light lights up and the P-N and P-E lights do not light up At that instant the RCD will
not trip
e) Move the selection switch to 180o (+ve wave) ndash repeat steps (d) and (e) = 100)
f) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
g) Move the selection switch to 0o (-ve wave)
h) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
i) The above test is repeated until a near correct reading is obtained
j) Record the test results
k) Change the operations switch to lsquoFast Triprsquo and press the test button ndash RCD will trip within a
time not exceeding 40 mS
l) Repeat a number of times at 0o or 180o
72 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 9 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (DC)
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
73 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Start stop button 240Vac 5A 2
9 Filament lamp (Bulb ) 240Vac 40W 3
10 Overload Relay 415V 20A 3
11 Three phase induction motor 5 hp 3
12 Single phase step down transformer 2500VA 1
13 Single core PVC insulated Cable 1mm 2 As required
14 Single core PVC insulated Cable 25mm 2 As required
15 DIN rail 35 mm As required
16 PVC type Cable tray 50 mm x 50 mm As required
17 Cable ties 4 ldquo As required
18 Flexible wires 05 mm As required
19 PVC Connectors 5 A amp 20 A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the schematic
diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a optional exercise
i Simple DOL starter
ii Forward reverse DOL starter
iii Forward Reverse Dahlander motor
iv Three motors operated in sequence by DOL starter operated by manual push
button or time delay relay
74 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
a One loop per-cycle
b Continuous operation in a loop
c optional circuit design to represent the same task
v Only one out of three motors to be operated at a time (quiz)
4 Test the functionality of completed project
LESSON 10 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (AC)
75 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 1
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Lamp point 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
76 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
11 Overload Relay 415V 20A 3
12 Three phase induction
motor
5 hp 3
13 Single core PVC insulated
Cable
1mm 2 As required
14 Single core PVC insulated
Cable
25mm 2 As required
15 DIN rail 35 mm As required
16 PVC type Cable tray 50 mm x 50 mm As required
17 Cable ties 4 ldquo As required
18 Flexible wires 05 mm As required
19 PVC Connectors 5 A amp 20 A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the
schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram optional exercise
4 Simple DOL starter
5 Forward reverse DOL starter
6 Test the functionality of completed project
77 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 1
78 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
cm
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Indicating light 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
11 Overload Relay 415V 20A 3
12 Three phase induction motor 5 hp 3
13 Single phase step down
transformer
2500VA 1
14 Single core PVC insulated
Cable
1mm 2 As required
15 Single core PVC insulated
Cable
25mm 2 As required
16 DIN rail 35 mm As required
17 PVC type Cable tray 50 mm x 50 mm As required
18 Cable ties 4 ldquo As required
19 Flexible wires 05 mm As required
20 PVC Connectors 5 A amp 20 A 240 V As required
21 Single pole MCB 6A 240 V 1
22 Single pole MCB 2A 240 V 1
23 Triple pole MCB 20A 415 V 1
24 Mounting board 30 cm x 40 cm x 3
cm
1
25 Relay cw 11 pin socket 10 A 240 Vac 2
26 Time delay relay 10 A 240 Vac 3
27 Triple pole Contactor 20A 240Vac 3
28 Batten type Lamp holder 240Vac 10 A 3
29 Start stop button 240Vac 10A 2
30 Indicating light (Bulb ) 240Vac 25W 3
31 Overload Relay 415V 20A 1
32 Three phase dahlander type
induction motor
5 hp 1
33 Single phase step down
transformer
24024Vac
2500VA
1
79 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
34 Single core PVC insulated
Cable
1mm 2 As required
35 Single core PVC insulated
Cable
25mm 2 As required
36 DIN rail 35 mm As required
37 PVC type Cable tray 50 mm x 50 mm As required
38 Cable ties 4 ldquo As required
39 Flexible wires 075 mm As required
40 PVC Connectors 5 A amp 20 A 240 V As required
41 Terminal block 20A 240Vac As required
Procedures
5 Identify each component according to specification and quantity required from the schematic
diagram attached
6 Test the functionality of each component by using multi-meter or power supply whichever
applicable
7 Wire component according to circuit diagram
8 Three motors operated in sequence by DOL starter operated by manual push button or time
delay relay
a One loop per-cycle
b Continuous operation in a loop
c optional circuit design to represent the same task
d Only one out of three motors to be operated at a time (quiz)
9 Test the functionality of completed project
80 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
BASIC DESIGN INDUSTRIAL MOTOR CONTROL (SEQUENCE CONTROL)
THREE PHASE INDUCTION MOTOR OPERATED IN SEQUENCE BY DIRECT ON LINE
STARTER
LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
81 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
82 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Lcd lamp indicator 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
11 Overload Relay 415V 20A 3
12 Three phase induction motor 5 hp 3
13 Single phase step down transformer 2500VA 1
14 Single core PVC insulated Cable 1mm 2 As required
15 Single core PVC insulated Cable 25mm 2 As required
16 DIN rail 35 mm As required
17 PVC type Cable tray 50 mm x 50 mm As required
18 Cable ties 4 ldquo As required
19 Flexible wires 1 mm Oslash As required
20 PVC Terminal block 10A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the schematic
diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a optional exercise
i Forward Reverse dahlander motor
4 Test the functionality of completed project
83 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
THREE PHASE DAHLANDER TYPE INDUCTION MOTOR OPERATED FORWARD AND
REVERSE OPERATION BY DIRECT ON LINE STARTER
84 ndash 99EASYTECH ENTERPRISE
LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
Introduction
If a motors windings are connected in the star configuration any two phases will be in series across
the supply and hence the line current will be smaller(by 577) than if the windings were connected in
the delta arrangement
Hence larger-type motors with heavy starting currents are first connected in star and then when the
starting currents fall in delta This of course means that all six of the ends of the windings must be
brought to terminations outside the casing (Fig 833)
EZTECH
EZTECH ELECTRICAL INSTALLATION GUIDE
The automatic version of this starter incorporates a timing relay which automatically changes the
connections from star to delta Figs 834 and 835 show the wiring and schematic diagrams for a star
delta starter
Objectives
1 Identify component and the specification
2 Design forward reverse star delta starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
2 ndash 99EASYTECH ENTERPRISE
REV -C
LEGENDMCCB Moulded Case Circuit BreakerTOR Thermal Over Load RelayFOW-C Mains Forward ContactorREV-C Mains Reverse ContactorDC Delta ContactorSC Star ContactorS-SW Mains Selector Switch
SC
V2
W2
U2
DC
V1
W1
U1
TOR
TOR
FOW-C
30A MCCB
TOR
MAIN CIRCUIT FORWARD REVERSE STAR DELTA
RYBN S
-SW
3 PHASEINDUCTION MOTOR
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Relay 10 A 240V 3
5 Triple pole Contactor
6 cw NO NC auxiliary contact
240Vac 20 A 4
7 Overload Relay 415 V 1
8 LED indicator 240vac 5 A 4
9 Start stop button 240Vac 5A 2
10 DIN rail 35 mm As required
11 Flexible wires 1 mm As required
12 Single core PVC insulated
wire
25 mm As required
13 Terminal block 20 A As required
14 Squirrel cage motor 5kW 1
15 5 pin plug and socket 415V 20A 1
16 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
3 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
a Manual star delta
b Manual Forward reverse star delta starter
c Automatic star delta starter
d Automatic Forward reverse star delta starter
4 Test the functionality of completed project
4 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
Objectives
1 Identify component and the specification
2 Design auto transformer starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
5 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Autotransformer starter is used to start a 3 phase induction motor that has a rating between 10 to 15 hp
6 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Autotransformer set 10Kw 415 V 50 Hz 1
5 Triple pole Contactor 240Vac 4
6 Batten type Lamp holder 240 Vac 105 A 4
7 Start stop button 240Vac 10A 4
8 Filament lamp (Bulb ) 240Vac 40W 4
9 DIN rail 35 mm As required
10 Flexible wires 1 mm As required
7 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
11 Single core PVC insulated
wire
25 mm As required
12 Terminal block 20 A As required
13 Squirrel cage motor 10kW 1
14 5 pin plug and socket 415V 20A 1
15 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a open transient autotransformer starter
b close transient autotransformer starter
c Forward reverse autotransformer starter
4 Test the functionality of completed project
8 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
Objectives
1 Identify component and the specification
2 Design rotor resistance starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
9 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Rotor Resistor set 10kW 1
5 Triple pole Contactor 240Vac 20A 4
6 Indicating light 240vac 5 A 4
7 Start stop push button 240Vac 5A 4
8 DIN rail 35 mm As required
9 Flexible wires 1 mm 2 As required
10 Single core PVC insulated wire 25 mm 2 As required
11 Terminal block 20 A As required
12 Slip Ring motor 10kW 1
13 5 pin round 3 phase socket 415V 20A 1
14 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
10 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
4 Test the functionality of completed project
a Dead circuit test b Life circuit test
5 Measure starting and running Amps
LESSON 16
TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
An installation in general will suffer damage
Damage usually occurs on the electric motor control as follows
1 Damage to the main circuit
2 Damage to the control circuit
The cause of the damage
i Overcurrent overload short circuit
ii Leakage current to ground
iii Equipment malfunction
iv The main control circuit
a Trip of main circuit protection devices fire
b Defect of motor terminal such as short circuit fire loose
v The control circuit is not functioning -
a contactor relay relay time overload relay does not work damaged burned
b Loose cable connection disconnected
Detecting and Repairing Damage
Examples of damage are as follows
i Motor does not work
ii Motor function and overload relay trips
iii Motor function but only partially functional control circuit
Methods of detecting damage
Among the known methods necessary to detect damage are as follows
1 Turn off the electricity at the main switch (main switch) in order to avoid any danger during the
work carried out to detect damage
2 Check all the protective gear that controls the motor control main circuit
11 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
3 Make sure the damage function control circuit
4 Check the control circuit according to the schematic circuit diagram of the motor control
5 Check the operation of the control circuit
Note
Use wiring that has been installed on the SYSTEM OF MOTOR CONTROL BOARD by Forward
Reverse control circuit for Star Delta to test and look for damage
SELF-ASSESSMENT QUESTIONS
1 (a) Explain what is meant by the term lsquoback emfrsquo in a motor
(b) Outline the basic differences between series shunt and compound wound dc motors
2 (a) With the aid of diagrams explain how the speed of series shunt and compound-wound motors
may be controlled
(b) A 440V dc shunt-wound motor has a field resistance of 200R and an armature resistance of 06 R
When its speed is 20 rev d second the current drawn from the supply is 122A Calculate its back
emf at this speed If the speed were decreased to 19 revssecond the field flux remaining unchanged
calculate the new back emf and the new armature current
3 A load of 64 kW at 240 V is supplied from the terminals of a shunt-wound dc generator The field
resistance is 180 A Calculate the armature current
4 (a) Explain with the aid of a diagram how a rotating magnetic field may be
(b) What is meant by lsquosynchronous speedrsquo
Calculate the synchronous obtained speed of a 12 pole motor if the supply frequency is 50Hz
5 (a) Explain the action of a synchronous motor
(b) What methods are available to start a synchronous motor Explain with diagrams
6 (a) Explain the action of a cage induction motor
(b) What is meant by the term lsquosliprsquo
Calculate the percentage slip of a six pole induction motor running at 162 revssecond from a 50 Hz
supply
7 Describe with sketches three different ways of starting a single-phase induction motor
12 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
8 Explain with the aid of a sketch the action of a three-phase DOL starter
What are dashpots used for How are remote start and stop buttons connected
9 A I0 kW 240V 50Hz single-phase cage rotor induction motor is 85efficient and has a PF of 068
lagging Calculate the motor current and the value of capacitor required to raise the PF to 093
lagging
10 Calculate the torque developed by an 18 kW four-pole induction motor run at 35 slip from a
50Hz supply
APPENDIX 1
13 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 11
14 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 111
Attachment Reference
httpswwwtlc-directcoukBook621htm
httpwwwstgovmyindexphpms
15 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Table of ContentsELECTRICITY SUPPLY SPECIFICATIONS4
Legal Requirements5
Determining Consumer Load Requirements6
2 CONTROL AND PROTECTION SYSTEM FOR ELECTRICAL WIRING7
CABLE SELECTION10
32 Factors Related to Cable Current Carrying Capacity11
Functions and Colour Identification of Non Flexible Cables12
Conductor Insulation and Types of Wiring13
Functions and Colour Identification of Non Flexible Cables13
3 SELECTION OF WIRING ACCESSORIES13
EARTHING OF ELECTRICAL INSTALLATIONS15
4 SAFETY REQUIREMENTS FOR ELECTRICAL WIRING WORKS IN
RESIDENTIAL BUILDINGS18
Why Electric Shocks Occur19
INSTALLATION CIRCUITS AND SYSTEMS20
Working Principal of Star-Delta Starter21
Star-delta Starter Consists following units21
Power Circuit of Star Delta Starter21
Control Circuit of Star-Delta Starter (Open Transition)22
What is Open or Closed Transition Starting23
Effect of Transient in Starter (Open Transient starter)25
Size of each part of Star-Delta starter25
Motor Starting Characteristics of Star-Delta Starter26
Advantages of Star-Delta starter26
Disadvantages of Star-Delta starter26
Features of star-delta starting27
Application of Star-Delta Starter27
28
LESSON 1 WIRING SYSTEM OF SINGLE PHASE DISTRIBUTION BOARD28
LESSON 2 WIRING SYSTEM OF SINGLE PHASE LIGHTING CIRCUIT32
2 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 3ndash WIRING SYSTEM OF SINGLE PHASE POWER CIRCUIT33
LESSON 4ndash CONDUIT BENDING AND TRUNKING FABRICATION TECHNIQUE37
LESSON 5 ndashWIRING SYSTEM OF 1 Oslash LIGHTING AND POWER CIRCUIT42
POWER CIRCUITS42
LESSON 6 ndash WIRING SYSTEM OF 3 Oslash DISTRIBUTION BOARD45
LESSON 7 ndash WIRING SYSTEM OF THREE PHASE LIGHTING AND POWER CIRCUIT52
LESSON 8 INSPECTION AND TESTING OF ELECTRICAL INSTALLATION55
CONTINUITY TEST60
Polarity Test64
Earth Electrode Resistance Test67
Earth Electrode Resistance Measurement Method (Figure 86)67
Residual Current Device Test68
LESSON 9 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (DC)74
LESSON 10 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (AC)76
LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE79
LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER83
LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER1
LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER4
LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER8
a Dead circuit test10
b Life circuit test10
LESSON 1610
TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR10
SELF-ASSESSMENT QUESTIONS11
Electricity Supply Act 1990Electricity Regulations 1994MS IEC 603642003 Standard Electrical Installations of BuildingsMS 19362006 Standard Electrical Installations of Buildings ndash Guide To MS IEC 60364 andMS 19792007 Standard Electrical Installation of Buildings ndash Code of Practice
3 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
ELECTRICITY SUPPLY SPECIFICATIONS
Electricity supply for domestic consumers according to MS IEC 60038 standards meets the
following specifications -
i Single phase supply with nominal voltage of 230V range +10 -6
ii Three phase supply with nominal voltage of 400V range +10 -6
iii Permitted frequency is 50Hz + 1
iv Earthing system type (TT System) as in Figure 21 and Figure 22
4 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Legal Requirements
Regulation 11(1) of the Electricity Regulations 1994 states that all wiring or rewiring of an
installation or extension to an existing installation which shall be carried out by an Electrical
Contractor or a Private Wiring Unit have to obtain the approval in writing from a licensee or supply
authority
1 Planning of Electrical Wiring Work
Prior to carrying out wiring work the wiremancontractor should plan and determine the tasks to be
undertaken so that the work carried out is tidy neat and safe to be used The wiremancontractor shall
-i Undertake a site visit
5 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
ii Determine the consumer load requirements
iii Calculate the maximum load demand and
iv Submit the plans drawings and specifications
The planning flow chart for building wiring installations is as shown in Figure 31
11 Site Visit
The purpose of the site visit is to determine -
i Electrical equipment suitable for use
ii Maximum load demand
iii Single or three phase incoming supply
iv Type of wiring and Equipment arrangement
Determining Consumer Load RequirementsWith the aid of the building floor plans the installation requirements such as the proposed load
placement of electrical equipment and installation design plans can be determined
11 Calculating Maximum Load Demand
The estimate of the maximum load demand is for determining the specifications of the wiring
equipment such as the cables and plans
According to clause 311 of MS IEC 60364 Part 1 to determine the maximum demand for each circuit
while ensuring an economic and reliable design within the permitted voltage drop limits Diversity
factors may be taken into account The maximum current demand calculations for each circuit must be
prepared These details will show the current requirements in amperes for each phase and also assist
in determining the cable sizes
Refer to the Third Schedule (Table A and Table B) and Regulation 11(2) of the Electricity Regulations
1994 to estimate the maximum current demand and the diversity factors that may be used for domestic
installations
12 Submission of the Plans Drawings and Specifications Regulation 65 of the Electricity
Regulations 1994 states that the eligibility to submit plans is as follows -
i Wireman with Single Phase Restriction ndash Low voltage single phase up to 60 A
ii Wireman with Three Phase Restriction ndash Low voltage up to 60A
6 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
2 CONTROL AND PROTECTION SYSTEM FOR ELECTRICAL WIRING
7 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
8 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
21 Selection of Control and Protection System for Electrical Wiring
Control and protection of a wiring is a system of separationisolation and switching together with the
protection system which are needed in every domestic wiring installation
22 Isolation and Switching
Examples of isolation and switching are switches power plugs socket outlets and circuit breakers
Their function is to manually connect and break the supply in a particular circuit without interfering
with other circuits
They also aim to prevent the danger of electrical shocks during maintenance testing fault finding and
repair works
23 Protection
This provides protection from dangers caused by electrical currents such as over current earth
leakage current short circuit lightning etc to the wiring system electrical equipment or consumer
The circuit below shows the isolation and protection devices which must be installed in a domestic
electrical wiring system
1 Current Protection
In general protection from the dangers of current can be divided into two aspects namely
i Overcurrent Protection (Over Load or Short Circuit) Properly rated circuit breakers or fuses suitable
for over load or short circuit protection must be used
9 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
The circuit breakers or fuses must be installed on the live conductors only For three phase circuits all
the circuit breakers or fuses must be combined in one set of circuits
Selection of over current devices must be based on the short circuit fault current levels of the circuit
breaker or main switch (kA)
ii Earth Leakage Current Protection
Properly rated Residual Current Devices (RCD) must be used for protection from earth leakage
currents (to prevent electric shocks)
a) Regulation 36(1) of the Electricity Regulations 1994 states that for a place of public entertainment
protection against earth leakage current must be provided by a residual current device of sensitivity
not exceeding 10 mA
b) Regulation 36(2) of the Electricity Regulations 1994 states that for a place where the floor is likely
to be wet or where the wall or enclosure is of low electrical resistance protection against earth leakage
current must be provided by a residual current device of sensitivity not exceeding 10 mA
c) Regulation 36(3) of the Electricity Regulations 1994 states that for an installation where hand-held
equipment apparatus or appliance is likely to be used protection against earth leakage current must be
provided by a residual current device of sensitivity not exceeding 30 mA and
d) Regulation 36(4) of the Electricity Regulations 1994 states that for an installation other than the
installation in (a) (b) and (c) protection against earth leakage current must be provided by a residual
current device of sensitivity not exceeding 100 mA
CABLE SELECTION
31 Selection of Wiring Cable Type
The selection of the cable size has to take into consideration the following-
i All wiring cables must be PVC or PVCPVC insulated with copper conductors Conductors with
cross sectional areas of 16mm2 or less must be of copper Aluminium conductors are not permitted
Refer to Table 4D1A in Appendix II for the current carrying capacities of copper conductor
ii Cables for swimming pools must be water resistant PE (polyethylene) insulated
10 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
iii The selected cable must be capable of delivering the electrical energy efficiently
iv The cable size allows it to carry the current without heating the cable
v The voltage drop must not exceed 4 of the supply voltage Refer to Table 4D1B in Appendix III
vi The cable insulation must be suitable for the surrounding conditions of the installation such as the
ability to withstand the surrounding temperatures and the ability to provide mechanical protection
vii Each conductor in the installation must be protected from overcurrent by means of overcurrent
protection devices needed to prevent damage to the cable insulation
32 Factors Related to Cable Current Carrying CapacityThe following factors in relation to the current carrying capacity of cables must be taken into
consideration-
i Surface wiring using clips ndash group factor
ii Wiring using conduits ndash space factor 40
iii Wiring using ducts ndash space factor 45
iv Concealed wiring ndash group factor and
v Concealed wiring using ducts ndash surrounding temperature factor
Use of Minimum Cross Sectional Area Rating of Wiring ConductorsThe following are the minimum cross sectional areas of conductors based on their applications-
Use of Protection Conductor Minimum Cross Sectional Area Rating
In Comparison with Phase Conductor Cross Sectional Area
The following table shows the protection conductor minimum cross sectional area in comparison
with the phase conductor cross sectional area
Functions and Colour Identification of Non Flexible Cables
The following table shows the functions and colour identification of non flexible cables
11 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
33 Use of Minimum Cross Sectional Area Rating of Wiring Conductors
The following are the minimum cross sectional areas of conductors based on their applications-
34 Use of Protection Conductor Minimum Cross Sectional Area Rating
In Comparison with Phase Conductor Cross Sectional Area
The following table shows the protection conductor minimum cross sectional area in comparison
with the phase conductor cross sectional area
Use of Minimum Cross Sectional Area Rating of Wiring Conductors
The following are the minimum cross sectional areas of conductors based on their applications-
Use of Protection Conductor Minimum Cross Sectional Area Rating
In Comparison with Phase Conductor Cross Sectional Area
The following table shows the protection conductor minimum cross sectional area in comparison
with the phase conductor cross sectional area
Functions and Colour Identification of Non Flexible CablesThe following table shows the functions and colour identification of non flexible cables
12 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Flexible Cables
i Flexible cables of cross sectional area less than 40 mm2 are used in installations for electrical
accessories such as ceiling roses lamp fixtures or attachments socket plugs for mobile
appliances etc
ii Flexible cables shall not be used for permanent wiring
iii Flexible cables for the permanent use of electrical appliances should not exceed 3 meters in
length
37 Functions and Colour Identification of Flexible Cables
Conductor Insulation and Types of WiringVarious material and insulation layers are used for conductor protection Cable selection in
accordance to insulation layers must be done correctly for the type of the wiring installation as
shown in the table below
Functions and Colour Identification of Non Flexible CablesThe following table shows the functions and colour identification of non flexible cables
3 SELECTION OF WIRING ACCESSORIES
i All wiring accessories to be used have to be of those approved by the Energy Commission and
labeled with labels issued by SIRIM For all wiring using UPVC conduits -
13 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
a) Switches socket outlets 3 pin plugs ceiling roses connectors sockets ndash construction material shall
be of polycarbonate type
iii For all wiring using metal conduits - Switches socket outlets and connectors ndash construction
material shall be of metal clad type and All accessories shall be effectively earthed
iv Switch fuse used in single phase installations shall have the fuse permanently connected and not
move with the fuse
v Fuse switch used in 3 phase domestic installations also has fuse and switch The fuse connector is
installed together to allow the fuse to move simultaneously with the switch
vi Lamp
a) Fluorescent lamps using magnetic ballasts (watt loss not exceeding 6 watts) shall be
equipped with dry paper type capacitor
b) Fluorescent lamps using electronic ballasts or high frequency electronic ballasts do not
need capacitors
c) Outdoor domestic lamp installations shall use weather proof and water proof lamps
d) Submerged light installations (example in swimming pools fountains etc) shall have water
proof lamps with a voltage not exceeding 12 Volt AC
vii Electric water heaters is divided into 2 types namely
1 instantaneous water heaters and
2 stored water heaters (storage tank type)
a) Instantaneous water heaters shall be equipped with a 2 pole control switch and its own
residual current device
b) Storage water heaters (storage tank type) shall be installed with an
Water heaters exceeding 3kW shall be permanently connected to a 20A30A rated circuit
breakerfuse with an isolator switch and residual current device
viii Electric cookers exceeding 3kW shall have its own circuit connected permanently to a 30A rated
circuit breaker or fuse with an isolator switch and cooker control unit incorporated with a 13A socket
outlet Two or more cooker appliances may be installed in the same room within a distance of 2
meters
ix Electric motors (fence gate air conditioners fountains swimming pools fish ponds water
pumps) exceeding 373W but not exceeding 2238W shall be connected permanently to a 20A30A
rated circuit breakerfuse together with an isolator motor starter and 15A socket outlet
14 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
The motor starter shall be of Direct-On-Line type with the appliance together with the contactor
overload relay and on-off control The circuit breakerfuse which controls the motor circuit shall be
capable of withstanding the starting current of the motor
x Electric bells ndash the circuit shall have a push button switch and a ACDC transformer
xi Ceiling fans shall conform to clause 21101 of the MS 12192002 standard with regards to test on
the suspension system of ceiling fans
EARTHING OF ELECTRICAL INSTALLATIONS51 Earthing
Earthing is a connection system between the metallic parts of an electrical wiring system and the
general mass of the earth This will provide an easy path with a low impedence or resistance to earth to
enable the protection system to operate effectively It will thus ensure safety to human
beingsconsumers from the dangers of electric shocks if earth leakage currents are present In general
an electrical installation is earthed because of -
i Safety reasons
ii Protection system requirements
iii Need to limit over voltages
iv Need to provide a path for electrical discharge
v Legal requirements
52 Classification of Earthing
Generally earthing can be divided into 2 parts namely -
i System Earthing
a To isolate the system under fault conditions
b To limit the potential difference between conductors which are not insulated in an area
c To limit the occurrence of over voltages under various conditions
ii Equipment Earthing
Equipment earthing is undertaken to protect human beingsconsumers If a live source comes into
contact with the equipment body electrical energy will flow to the earth without flowing through the
human being consumerrsquos body This is because of the fact that the human body has a greater
resistance compared with the resistance to earth
53 Types and Functions of Earthing Accessories
Earthing accessories are as follows -
i Earthing Electrode
Copper jacketed steel core rods are used as electrodes for domestic wiring
ii Equipotential Bonding
15 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
This is the conductor which is connected between the consumer earthing point and the exposed
metallic part The minimum cable size for this purpose is 10 mm2
iii Protection Conductor
This is the conductor which connects the consumer earthing point with other parts of the installation
which needs earthing Its size is as follows-
a) Same size as the phase cable up to a size of 16mm2
b) 16 mm2 if the phase cable size is between 16 mm2 and 35 mm2
c) Half the size of the phase cable if the size of the phase cable exceeds 35 mm2
54 Earthing Arrangements Using a TT System
i The first alphabet indicates the earthing arrangements from the supply side
ii The second alphabet indicates the earthing arrangement in the consumerrsquos installation
T ndash first Indicates that the supply system has its own earthing arrangements
T ndash second Indicates that all metallic frames of the electrical appliances etc are connected directly to
earth
Parts that are Required to be Earthed
i All metallic structures in the wiring system (non current carrying) such as metallic covers conduits
ducts the armour of catenary wires etc
ii A secondary winding point in a transformer and
iii Frame of metal roof truss
56 Parts that are not Required to be Earthed
i Short isolated metallic parts for mechanical protection of cables which have non metallic sheaths
other than conduits which are connected at entry points between the building and conduits which
protect discharge lamp cables
ii Cable clips for installing cables
iii Metallic covers for lamps
16 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
iv Small metallic parts such as screws and name plates which are isolated by means of insulation
v Metallic lamp parts for filament lamps in water proof floors
57 Termination to Earth
The termination to earth is done as shown in Figure 72
Earth Electrode Resistance
The maximum permitted earth electrode resistance for different types of installations is as shown in
the Table below
Earth electrode for installations protected by RCDs of sensitivity 100mA 10 Ω
Lightning arrestor earth electrode 10 Ω
Legal Requirements
i Sub regulation 12(1) and 12(2) of the Electricity Regulations 1994 state that any electrical wiring in
an installation shall be under the immediate supervision of a Wireman with Single Phase Restriction or
Three Phase Restriction Upon completion the Wireman shall certify a Supervision and Completion
Certificate
ii Sub regulation 13(1) and 13 (2) of the Electricity Regulations 1994 state that the installation shall
be tested by a Wireman with Single Phase Restriction or a Wireman with Three Phase Restriction
authorized to test any installation and who shall certify a Test Certificate for the installation
iii Sub regulation 14(1) of the Electricity Regulations 1994 states that the Supervision and
Completion Certificate and the Test Certificate as in regulations 12 and 13 shall be in Forms G and H
respectively as prescribed in the First Schedule
17 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
4 SAFETY REQUIREMENTS FOR ELECTRICAL WIRING WORKS IN RESIDENTIAL BUILDINGS
61 Safety Requirements
Safety requirements for electrical wiring works have to be followed to eliminate any accidents which
can result in physical damage or loss of life or property Failure to meet the safety regulations may
result in workers consumers or the public being inflicted with electrical shocks
In addition to this safety steps will also encourage workers or electricity consumers who are
disciplined and who always give importance to safety
62 Safety Steps
Safety requirements have to be followed whenever electrical works are undertaken in a residential
building
i Personal Safety
a Use suitable personal protection equipment as needed such as safety shoes gloves safety helmet
etc when at the work place
b Use safety clothing suitable for the work to be undertaken
c Do not wear jewellery or decorative items such as rings watches chains etc while carrying out
electrical works
ii Safety at the Work Place
a Acquire knowledge about the dangers of electrical works that is to be undertaken and how to deal
with those dangers
b Always adhere to the safety regulations which have been set for the work place
c Ensure that the electricity supply is switched off before carrying out the works
d Acquire the needed knowledge and practice a cautious and calm attitude while working ensure
cleanliness in and around fellow workers
e While working at elevated places the worker should always use suitable equipment such as wooden
or aluminium ladders iron scaffoldings or platforms safety belts or other equipment needed to ensure
that the work can be undertaken safely
f Use electrical equipment which is operational and safe to be used and ensure that the supply for it is
being supplied through a residual current device (RCD) with a sensitivity of 30 mA
g Ensure that exposed temporary supply electrical cables have mechanical protection
h If inflammable or corrosive material is present necessary safety steps have to be undertaken as
required by the relevant safety regulations
63 Dangers of Electrical Shocks
i Electrical Shock
Electrical shocks can occur due to direct or indirect contact
a Direct Contact
18 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Direct contact occurs when the worker or consumer receives an electrical shock on touching directly a
live conductor or cable
b Indirect Contact
Here the electric shock occurs due to contact with a part which is connected to the electrical
installation and not to a direct contact with a live cable or conductor possibly due to damages in the
appliance or insulation resulting in leakages of current
Why Electric Shocks Occura Unsafe Work Method or Action Undertaking Electrical Work Without Disconnecting the
Supply
Maintenance or circuit testing work done without disconnecting the supply will have a high possibility
of electrical shocks occurring
bull Not Following Safe Work Procedures
To eliminate the occurrence of electrical shocks each worker has to always follow safe work
procedures which are set by regulations and standards
b Defects in the Electrical System
i Leakage Current
Leakage currents or earth leakage currents can result in the metallic frames becoming live and
energised This can give rise to the danger of electrical shock to the worker consumer or the public if
they hold or come into contact with the metallic frame
ii Exposed Conductor or Disconnected Cable
Exposed conductors or cables which are broken and are alive (energised) can result in electrical shock
when touched The supply source must be immediately isolated or switched off and a report must be
made to the responsible entity
64 First Aid and Basic Pulmonary Resuscitation
i First Aid
First aid is the initial assistance given to a person who has met with an accident is sick or is injured to
prevent the condition of the victim from becoming more serious while awaiting the arrival of the
paramedics (ambulance) or before being brought to the hospital
i Pulmonary Resuscitation
Pulmonary resuscitation has to be undertaken to assist the victim who has breathing difficulties as a
result of being drowned receiving an electrical shock etc Pulmonary resuscitation has to be carried
out in accordance to the correct method as stated in the first aid manuals issued by accredited first aid
bodies
ii First Aid Box
19 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
A first aid box has to be provided by the building owner construction site supervisor or brought
personally by the worker under the supervision of the responsible person
65 Training Programme
The management shall conduct periodic training programmes for the workers with regards to work
safety on aspects including the following -
i Dangers of electrical work being undertaken and how to control those dangers
ii The safety regulations set for the work place and
iii First aid procedures
66 Fire Prevention
Fire Extinguisher A suitable functioning fire extinguisher to control fires has to be made available at
the work place at all times
67 Competent Person
The Electricity Regulations 1994 require that all electrical work has to be undertaken by or under the
direct supervision of a competent person registered with the Energy Commission Besides that the
electrical contractor undertaking the electrical work has also to be registered with the Energy
Commission The installation owner thus has to ensure that the appointed electrical contractor is
registered with the Energy Commission and that the registration is still valid
INSTALLATION CIRCUITS AND SYSTEMS1 Block diagrams
These show using squares rectangles etc the sequence of a system without too much technical detail
eg Figures 1517 and 1526
2 Layout diagrams
These are very similar to block diagrams but they indicate more technical detail and tend to show
items in their correct geographical location (eg Figures 1518 and 1519)
3 Circuitschematic
These show how a circuit functions and takes no account of exact locations of terminals or equipment
(eg Figures 1528 1529 1532 1534 etc)
4 Wiring diagram
These indicate how a circuit or system is physically wired (eg Figures 152 154 156 etc)
Most induction motors are started directly on line but when very large motors are started that way
they cause a disturbance of voltage on the supply lines due to large starting current surges To limit the
starting current surge large induction motors are started at reduced voltage and then have full supply
voltage reconnected when they run up to near rotated speed Two methods are used for reduction of
starting voltage are star delta starting and auto transformer stating
20 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Working Principal of Star-Delta Starter
This is the reduced voltage starting method Voltage reduction during star-delta starting is achieved by
physically reconfiguring the motor windings as illustrated in the figure below During starting the
motor windings are connected in star configuration and this reduces the voltage across each winding 3
This also reduces the torque by a factor of three After a period of time the winding are reconfigured as
delta and the motor runs normally
StarDelta starters are probably the most common reduced voltage starters They are used in
an attempt to reduce the start current applied to the motor during start as a means of reducing the
disturbances and interference on the electrical supply
Traditionally in many supply regions there has been a requirement to fit a reduced voltage
starter on all motors greater than 5HP (4KW) The StarDelta (or WyeDelta) starter is one of the
lowest cost electromechanical reduced voltage starters that can be applied
The StarDelta starter is manufactured from three contactors a timer and a thermal overload
The contactors are smaller than the single contactor used in a Direct on Line starter as they are
controlling winding currents only The currents through the winding are 1root 3 (58) of the
current in the line
There are two contactors that are close during run often referred to as the main contractor and
the delta contactor These are AC3 rated at 58 of the current rating of the motor The third
contactor is the star contactor and that only carries star current while the motor is connected in star
The current in star is one third of the current in delta so this contactor can be AC3 rated at one
third (33) of the motor rating
Star-delta Starter Consists following units
1) Contactors (Main star and delta contactors) 3 Norsquos (For Open State Starter) or 4 Norsquos (Close
Transient Starter)
2) Time relay (pull-in delayed) 1 No
3) Three-pole thermal over current release 1No
4) Fuse elements or automatic cut-outs for the main circuit 3 Nos
5) Fuse element or automatic cut-out for the control circuit 1No
Power Circuit of Star Delta Starter
1 The main circuit breaker serves as the main power supply switch that supplies electricity to the
power circuit
2 The main contactor connects the reference source voltage R Y B to the primary terminal of the
motor U1 V1 W1
21 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
3 In operation the Main Contactor (KM3) and the Star Contactor (KM1) are closed initially and
then after a period of time the star contactor is opened and then the delta contactor (KM2) is
closed The control of the contactors is by the timer (K1T) built into the starter The Star and Delta
are electrically interlocked and preferably mechanically interlocked as well In effect there are
four states
4 The star contactor serves to initially short the secondary terminal of the motor U2 V2 W2 for the
start sequence during the initial run of the motor from standstill This provides one third of DOL
current to the motor thus reducing the high inrush current inherent with large capacity motors at
startup
5 Controlling the interchanging star connection and delta connection of an AC induction motor is
achieved by means of a star delta or wye delta control circuit The control circuit consists of push
button switches auxiliary contacts and a timer
Control Circuit of Star-Delta Starter (Open Transition)
1 The ON push button starts the circuit by initially energizing Star Contactor Coil (KM1) of star
circuit and Timer Coil (KT) circuit
2 When Star Contactor Coil (KM1) energized Star Main and Auxiliary contactor change its
position from NO to NC
3 When Star Auxiliary Contactor (1)( which is placed on Main Contactor coil circuit )became
NO to NC itrsquos complete The Circuit of Main contactor Coil (KM3) so Main Contactor Coil
energized and Main Contactorrsquos Main and Auxiliary Contactor Change its Position from NO
To NC This sequence happens in a friction of time
4 After pushing the ON push button switch the auxiliary contact of the main contactor coil (2)
which is connected in parallel across the ON push button will become NO to NC thereby
providing a latch to hold the main contactor coil activated which eventually maintains the
control circuit active even after releasing the ON push button switch
5 When Star Main Contactor (KM1) close its connect Motor connects on STAR and itrsquos
connected in STAR until Time Delay Auxiliary contact KT (3) become NC to NO
6 Once the time delay is reached its specified Time the timerrsquos auxiliary contacts (KT)(3) in
Star Coil circuit will change its position from NC to NO and at the Same Time Auxiliary
contactor (KT) in Delta Coil Circuit(4) change its Position from NO To NC so Delta coil
energized and Delta Main Contactor becomes NO To NC Now Motor terminal connection
change from star to delta connection
7 A normally close auxiliary contact from both star and delta contactors (5amp6)are also placed
opposite of both star and delta contactor coils these interlock contacts serves as safety
switches to prevent simultaneous activation of both star and delta contactor coils so that one
22 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
cannot be activated without the other deactivated first Thus the delta contactor coil cannot be
active when the star contactor coil is active and similarly the star contactor coil cannot also
be active while the delta contactor coil is active
8 The control circuit above also provides two interrupting contacts to shutdown the motor
The OFF push button switch break the control circuit and the motor when necessary The
thermal overload contact is a protective device which automatically opens the STOP Control
circuit in case when motor overload current is detected by the thermal overload relay this is to
prevent burning of the motor in case of excessive load beyond the rated capacity of the motor
is detected by the thermal overload relay
9 At some point during starting it is necessary to change from a star connected winding to a
delta connected winding Power and control circuits can be arranged to this in one of two
ways ndash open transition or closed transition
What is Open or Closed Transition Starting
(1) Open Transition Starters
Discuss mention above is called open transition switching because there is an open state between
the star state and the delta state
In open transition the power is disconnected from the motor while the winding are reconfigured via
external switching
When a motor is driven by the supply either at full speed or at part speed there is a rotating
magnetic field in the stator This field is rotating at line frequency The flux from the stator field
induces a current in the rotor and this in turn results in a rotor magnetic field
When the motor is disconnected from the supply (open transition) there is a spinning rotor within
the stator and the rotor has a magnetic field Due to the low impedance of the rotor circuit the time
constant is quite long and the action of the spinning rotor field within the stator is that of a
generator which generates voltage at a frequency determined by the speed of the rotor When the
motor is reconnected to the supply it is reclosing onto an unsynchronized generator and this result
in a very high current and torque transient The magnitude of the transient is dependent on the
phase relationship between the generated voltage and the line voltage at the point of closure can
be much higher than DOL current and torque and can result in electrical and mechanical damage
Open transition starting is the easiest to implement in terms or cost and circuitry and if the timing
of the changeover is good this method can work well In practice though it is difficult to set the
necessary timing to operate correctly and disconnectionreconnection of the supply can cause
significant voltagecurrent transients
In Open transition there are Four states
23 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 OFF State All Contactors are open
2 Star State The Main [KM3] and the Star [KM1] contactors are closed and the delta [KM2]
contactor is open The motor is connected in star and will produce one third of DOL torque at one
third of DOL current
3 Open State This type of operation is called open transition switching because there is an
open state between the star state and the delta state The Main contractor is closed and the Delta
and Star contactors are open There is voltage on one end of the motor windings but the other end
is open so no current can flow The motor has a spinning rotor and behaves like a generator
4 Delta State The Main and the Delta contactors are closed The Star contactor is open The
motor is connected to full line voltage and full power and torque are available
(2) Closed Transition StarDelta Starter
There is a technique to reduce the magnitude of the switching transients This requires the use of a
fourth contactor and a set of three resistors The resistors must be sized such that considerable
current is able to flow in the motor windings while they are in circuit
The auxiliary contactor and resistors are connected across the delta contactor In operation just
before the star contactor opens the auxiliary contactor closes resulting in current flow via the
resistors into the star connection Once the star contactor opens current is able to flow round
through the motor windings to the supply via the resistors These resistors are then shorted by the
delta contactor If the resistance of the resistors is too high they will not swamp the voltage
generated by the motor and will serve no purpose
In closed transition the power is maintained to the motor at all time This is achieved by
introducing resistors to take up the current flow during the winding changeover A fourth
contractor is required to place the resistor in circuit before opening the star contactor and then
removing the resistors once the delta contactor is closed These resistors need to be sized to carry
the motor current In addition to requiring more switching devices the control circuit is more
complicated due to the need to carry out resistor switching
In Close transition there are Four states
1 OFF State All Contactors are open
2 Star State The Main [KM3] and the Star [KM1] contactors are closed and the delta [KM2]
contactor is open The motor is connected in star and will produce one third of DOL torque at one
third of DOL current
Star Transition State The motor is connected in star and the resistors are connected across the
delta contactor via the aux [KM4] contactor
24 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Closed Transition State The Main [KM3] contactor is closed and the Delta [KM2] and Star
[KM1] contactors are open Current flows through the motor windings and the transition resistors
via KM4
Delta State The Main and the Delta contactors are closed The transition resistors are shorted out
The Star contactor is open The motor is connected to full line voltage and full power and torque
are available
Effect of Transient in Starter (Open Transient starter)
It is Important the pause between star contactor switch off and Delta contactor switch is on correct
This is because Star contactor must be reliably disconnected before Delta contactor is activated It
is also important that the switch over pause is not too long
For 415v Star Connection voltage is effectively reduced to 58 or 240v The equivalent of 33
that is obtained with Direct Online (DOL) starting
If Star connection has sufficient torque to run up to 75 or 80 of full load speed then the motor
can be connected in Delta mode
When connected to Delta configuration the phase voltage increases by a ratio of V3 or 173 The
phase currents increase by the same ratio The line current increases three times its value in star
connection
During transition period of switchover the motor must be free running with little deceleration
While this is happening ldquoCoastingrdquo it may generate a voltage of its own and on connection to the
supply this voltage can randomly add to or subtract from the applied line voltage This is known as
transient current Only lasting a few milliseconds it causes voltage surges and spikes Known as
a changeover transient
Size of each part of Star-Delta starter
(1) Size of Over Load Relay
For a star-delta starter there is a possibility to place the overload protection in two positions in the
line or in the windings
Overload Relay in Line
In the line is the same as just putting the overload before the motor as with a DOL starter
The rating of Overload (In Line) = FLC of Motor
Disadvantage If the overload is set to FLC then it is not protecting the motor while it is in delta
(setting is x1732 too high)
Overload Relay in Winding
25 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
In the windings means that the overload is placed after the point where the wiring to the contactors
are split into main and delta The overload then always measures the current inside the windings
The setting of Overload Relay (In Winding) =058 X FLC (line current)
Disadvantage We must use separate short circuit and overload protections
(2) Size of Main and Delta Contractor
1 There are two contactors that are close during run often referred to as the main contractor and
the delta contactor These are AC3 rated at 58 of the current rating of the motor
Size of Main Contactor= IFL x 058
(3) Size of Star Contractor
The third contactor is the star contactor and that only carries star current while the motor is
connected in star The current in star is 1 radic3= (58) of the current in delta so this contactor can
be AC3 rated at one third (33) of the motor rating
Size of Star Contactor= IFL x 033
Motor Starting Characteristics of Star-Delta Starter
Available starting current 33 Full Load Current
Peak starting current 13 to 26 Full Load Current
Peak starting torque 33 Full Load Torque
Advantages of Star-Delta starter
The operation of the star-delta method is simple and rugged
It is relatively cheap compared to other reduced voltage methods
Good TorqueCurrent Performance
It draws 2 times starting current of the full load ampere of the motor connected
Disadvantages of Star-Delta starter
Low Starting Torque (Torque = (Square of Voltage) is also reduce)
Break In Supply ndash Possible Transients
Six Terminal Motor Required (Delta Connected)
It requires 2 set of cables from starter to motor
It provides only 33 starting torque and if the load connected to the subject motor requires higher
starting torque at the time of starting than very heavy transients and stresses are produced while
changing from star to delta connections and because of these transients and stresses many
electrical and mechanical break-down occurs
26 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
In this method of starting initially motor is connected in star and then after change over the motor
is connected in delta The delta of motor is formed in starter and not on motor terminals
High transmission and current peaks When starting up pumps and fans for example the load
torque is low at the beginning of the start and increases with the square of the speed When
reaching approx 80-85 of the motor rated speed the load torque is equal to the motor torque and
the acceleration ceases To reach the rated speed a switch over to delta position is necessary and
this will very often result in high transmission and current peaks In some cases the current peak
can reach a value that is even bigger than for a DOL start
Applications with a load torque higher than 50 of the motor rated torque will not be able to start
using the start-delta starter
Low Starting Torque The star-delta (wye-delta) starting method controls whether the lead
connections from the motor are configured in a star or delta electrical connection The initial
connection should be in the star pattern that results in a reduction of the line voltage by a factor of
1radic3 (577) to the motor and the current is reduced to 13 of the current at full voltage but the
starting torque is also reduced 13 to 15 of the DOL starting torque
The transition from star to delta transition usually occurs once nominal speed is reached but is
sometimes performed as low as 50 of nominal speed which make transient Sparks
Features of star-delta starting
1 For low- to high-power three-phase motors
2 Reduced starting current
3 Six connection cables
4 Reduced starting torque
5 Current peak on changeover from star to delta
6 Mechanical load on changeover from star to delta
Application of Star-Delta Starter
The star-delta method is usually only applied to low to medium voltage and light starting
Torque motors
The received starting current is about 30 of the starting current during direct on line start and the
starting torque is reduced to about 25 of the torque available at a DOL start This starting
method only works when the application is light loaded during the start If the motor is too heavily
27 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
loaded there will not be enough torque to accelerate the motor up to speed before switching over
to the delta position
LESSON 1 WIRING SYSTEM OF SINGLE PHASE DISTRIBUTION BOARD
Introduction
28 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
29 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
30 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
31 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 2 WIRING SYSTEM OF SINGLE PHASE LIGHTING CIRCUIT Introduction
Objectives
1 Identify component and the specification
2 Wire component according to the schematic diagram
3 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Wiring bay Perforated metal 180 cm x 180 cm 1
2 Cut out fuse 63 A 240 V 1
3 Neutral link 1
4 Single pole one way switch cw
switch box
5A 240Vac 4
5 single pole two way switch cw
switch box
5A 240Vac 2
6 RCCB In = 40 A Tripping current
100mA240 Vac 50 Hz
1
7 Main switch 32 A 240V 1
8 kWatthour meter 40 A 240 Vac 1
9 Single pole MCB 6A 240 Vac 1
10 Self tapping Wood screw As required
11 DIN rail 35 mm width As required
32 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
12 PVC trunking 50 mm x 50 mm As required
13 Terminal blocks 5 A As required
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
1 One way switch to control one lamp
2 One way switch to control two lamps
3 Two of two way switch to control one lamp
4 Two of single pole two way switch and one of an intermediate switch to control one
lamp
5 One unit of ceiling fan and fan regulator to be controlled by one way switch
4 Test the functionality of completed project
LESSON 3ndash WIRING SYSTEM OF SINGLE PHASE POWER CIRCUIT Introduction
33 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
34 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify types of component and its specification
2 Wire component according to the schematic diagram given
3 Test the functionality of the circuit dead circuit test life circuit test
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board Perforated Metal 1
2 kWh meter 240 V 40 A 1
3 Socket outlet 13A 240Vac 4
4 RCCB 40A Trip Amps
30mA240 Vac
1
5 3 pin socket 240Vac 13A 4
6 Single pole MCB 20A 240 V 2
7 DOL starter 1 kW 240Vac 2
8 1 phase induction motor 2Hp 240 Vac 1
9 Cooker control unit 4kW 240Vac 1
10 Water heater point 4kW 240 Vac 1
11 DIN rail 35 mm As required
12 PVC casing 20mm As required
13 Flexible wires 05 mm As required
14 Terminal block 10 A As required
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Wire two unit of 13 A socket outlet in radial circuit
3 Wire four units of 13 A socket outlet in ring circuit
4 Wire one unit DOL starter for air-conditioner point
5 Wire one unit of cooker control unit point
6 Wire one unit of water heater point
7 Test the functionality of each component by using mmeter or power supply whichever
applicable
8 Wire component according to circuit diagram
9 Test the functionality of completed project dead circuit test life circuit test
Note
35 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Ensure that the correct rating of protection device and size of wire used
LESSON 4ndash CONDUIT BENDING AND TRUNKING FABRICATION TECHNIQUE
Common fitting used in an industrial wiring
Cutting and threading the condute
36 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
37 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
38 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify conduit fitting and the specification
2 Measure and Cut steel conduit according to specified dimension
3 Bend and fabricate conduit at 45 90 according to layout diagram
4 Wire component according to the schematic diagram
5 Test the functionality of the circuit
39 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Conduit Bender Oslash 19 mm ( frac34 ldquo) 1
2 Measuring Tape 3 metre 1
3 Hacksaw frame and blade 30cm 1
4 Conduit cutter 1
5 Pipe Vise 1
6 Pipe Wrench 1
7 Ratchet Dies 20 mm 1
8 Metal trunking 50 mm x 50 mm 1
9 GI conduit 20mm 1
10 End box 20 mm 1
11 Flexible wires 05 mm As required
12 Connectors 5 A As required
13 Single core PVC ins Cable 25 mm 2 As required
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Wire two unit of 13 A socket outlet in radial circuit
3 Wire four unit of 13 A socket outlet in ring circuit
4 Wire one unit DOL starter for air-conditioner point
5 Wire one unit of cooker control unit point
6 Wire one unit of water heater point
7 Test the functionality of each component by using multimeter or power supply whichever
applicable
8 Wire component according to circuit diagram
9 Test the functionality of completed project
Note
Ensure that the rating of protection device and size of wire
K prior to 31 March
2004 (BS 7671)
(formerly)
bare conductor
sleeved at terminations (formerly)
40 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 5 ndashWIRING SYSTEM OF 1 Oslash LIGHTING AND POWER CIRCUIT
POWER CIRCUITSa Radial circuits
Radial circuits are arranged in the same way as item 1 above in lighting layouts in that each socket
outlet is supplied via the previous one
Points to note
1 The number of socket outlets complying with BS 1363 is unlimited for a floor area of up to 50m 2 if
the circuit protection is a 30 A or 32 A cartridge fuse or circuit breaker the cable being 4 mm PVC
copper or 25 mm2 mineral insulated (mi)
2 The number of socket outlets is unlimited for a floor area up to 20 m 2 with any type of circuit
protection of 20 A using 25 mm2 PVC copper cable or 15 mm2 mi
3 The total number of fused spurs is unlimited
b ring final circuits
These circuits are the same as radial circuits except that the final socket outlet is wired back to the
supply position In effect any outlet is supplied from two directions (Fig 152)
Points to note
1 Every twin-socket outlet counts as two single-socket outlets
2 The number of non-fused spurs must not exceed the total number of points on the ring Fig 158
shows seven points on the ring and five spurs
3 The fuse rating of a fused spur box must not exceed 13 A and the current rating of all points supplied
by the fused spur must not exceed 13 A
4 Non-fused spurs must supply no more than one single or one double socket on the ring Fig 158
shows seven points on the ring and five spurs rating of all points supplied by the fused spur must not
exceed 13 A or one stationary appliance
CapacityMain conductor size
copper (mm2)
Earth conductor
size (mm2)
Circuit breaker
capacity (A)
Up to 600 W 15 15 6
600ndash1200 W 1525 15 10
1200ndash1800 W 254 25 16
41 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Ring circuit
(floor area 100 m2)25 15 3032
A2 radial circuit
(floor area 75 m2)40 25 3032
A3 radial circuit
(floor area 50 m2)25 15 20
Air conditioner (15 tonne) 60 60 3032
Cooker 60 60 3032
Water heater 40 40 20
Objectives
1 Identify component and the specification
2 Wire component according to the schematic diagram
3 Test the functionality of the circuit
42 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board Perforated 1
2 Cut out fuse and neutral link 60A 240V 1each
3 kWh meter 240V 40A 1
4 Switched Socket outlet 13A 240Vac 4
5 Single pole two way switch cw switch
box
5A 240Vac 2
6 RCCB ELCB 63 A Tripping current 100mA
415 Vac
1
7 3 pin plug 240Vac 13A 4
8 Single pole MCB 20 A 2
9 Single pole MCB 6A 1
10 Single pole MCB 20A 2
11 DOL starter 240Vac 2
12 1 phase induction motor 2hp 240 Vac 1
13 Self tapping Wood screw As required
14 DIN rail Stainless steel allum35 mm As required
15 PVC pipe 20mm dia As required
16 End box 20 mm dia 4
17 Flexible wires 05 mm 2 As required
18 Connectors 5 A As required
Procedures
43 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
4 Test the functionality of completed project
LESSON 6 ndash WIRING SYSTEM OF 3 Oslash DISTRIBUTION BOARD
Introduction
44 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
45 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
46 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
47 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
48 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify each component and the specification
2 Wire component according to the schematic diagram given
3 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting Board 450 x 600 mm Perforated metal 1
2 5 pin round socket and plug 415V ac 32A 1
3 Cut out fuse 60 A 3
4 Neutral link 1
5 kWatt hour meter 415V 60A 1
6 ELCB RCCB 3P+N In=63A415 Vac I trip= 300mA 1
7 ELCB RCCB 3P+N In=63A415 Vac I trip= 30mA 1
8 Single pole MCB 6A 240 V 3
9 Single pole MCB 20A 240 V 3
10 DOL starter 20 A 240Vac 2
11 Socket outlet 15 A 240 Vac 1
12 Switched Socket outlet 13 A 240 Vac 3
13 Led indicating light 5A 240 Vac 3
14 Single pole 4 gang 1 way switch 5A 240 Vac 2
15 Single pole 2 way switch 5A 240 Vac 2
16 1 phase induction motor 1 kW 240Vac 1
17 Metal trunking 30 mm x30 mm As required
18 Self tapping Wood screw 4 mm x 20 mm As required
19 DIN rail 25 mm x 1mm
20 GI steel rigid conduit 20mm As required
21 Flexible conduit 20mm As required
22 End box 20 mm 4
23 Flexible wires 05 mm 2 As required
24 Single core PVC insulated wire 15 mm 2 As required
25 Single core PVC insulated wires 25 mm 2 As required
26 Terminal block 10 A As required
Procedures
49 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify each components and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
4 Test the functionality of completed project
1 dead circuit test
2 life circuit
Note Proper earthing should be made
50 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 7 ndash WIRING SYSTEM OF THREE PHASE LIGHTING AND POWER CIRCUIT
51 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
52 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify component and the specification
2 Wire component according to the schematic diagram
3 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting bay Board Perforated metal 180 cm x 180 cm 1
2 k Watt hour meter 415V 60A 1
3 MCCB 415V 60A
4 ELCB RCCB In=60A415 Vac I trip=30mA 1
5 5 pin round Socket and
plug
415Vac 32A 4
6 Single pole MCB 6A 1
7 Triple pole MCB 20A 2
8 Triple pole Main switch 60A 1
9 DOL starter 240Vac 2
10 3 phase induction motor 2hp 415 Vac 1
11 1 phase induction motor 1
12 Metal trunking 30 mm x30 mm As required
13 Self tapping Wood screw 4 mm x 20 mm As required
14 DIN rail 25 mm x 1mm
15 GI steel rigid conduit 20mm As required
16 Flexible conduit 20mm As required
17 End box 20 mm 4
18 Flexible wires 05 mm As required
19 Connectors 10 A As required
Procedures
1 Identify each components and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
4 Test the functionality of completed project
1 dead circuit 2 life circuit test
5 Record the current drawn by the load as connected in star and delta
Note Proper earthing should be made
53 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 8 INSPECTION AND TESTING OF ELECTRICAL INSTALLATION
On completion of a wiring installation a number of tests on the installation have to be conducted to
ascertain that the wiring circuits and connected appliances are safe for use Prior to carrying out the
tests an inspection has to be done The results of the inspectionsupervision and test have to be
presented in Form G (as in Appendix IV) and Form H (as in Appendix V)
To have the test certification as in Form H the following tests shall be conducted
i Continuity Test
ii Insulation Resistance Test
iii Polarity Test
iv Earth Electrode Resistance test and
v Residual Current Device Test
1 Continuity Test
There are 3 main types of continuity tests for the final circuits-
i Protection Conductor Continuity Test
ii Final Ring Circuit Conductor Continuity Test
iii Live and Neutral Conductor Continuity Test
a) Protection Conductor Continuity Test
bull To ascertain that all protection conductors are connected in the correct and effective manner
bull Test equipment ndash Multimeter (Ohm range) or Ohm meter
54 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
bull Test Method
1 1048766 Ensure that the main switch RCD and MCB are open circuited (switched off) and all loads
are disconnected
2 1048766 Connected the test leads as in the Figure 81 The meter reading shall be less than 1 Ω
55 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Final Ring Circuit Conductor Continuity Test
bull To ensure that all conductors around the ring circuit have continuity
bull Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
bull Test Method
1 1048766 Disconnect both the supply source live conductors from the MCB the neutral conductor
from the neutral terminals and the earth conductor from the earth terminal in the distribution
fuse box
2 1048766 Connect the test leads as in the Figure 82 (EE)
3 1048766 Repeat the procedure for (L-L) and (N-N)
4 1048766 The meter reading value shall be less than 1 ohm
56 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Live and Neutral Conductor Continuity Test
a To ensure that each conductor in the circuit has continuity
b Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
2 Test Method
1 1048766 Switch off the Main switch RCD and MCB
2 1048766 Disconnect all loads
3 1048766 Switch on all switches in the circuit
4 1048766 Disconnect the fusesfinal circuit breakers and close the circuit
5 1048766 Carry out the test as shown in Figure 83
6 1048766 The meter reading value shall be less than 1Ω
57 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
58 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
CONTINUITY TEST
Insulation Resistance Test
i Ensure that there is no leakage current between phase conductors phase and neutral conductors and
phase conductor and earth
ii Test the strength of the cable insulation
iii Test Equipment ndash Insulation Resistance Tester operating voltage is 250VDC or 500VDC
iv Test Method
1 1048766 Switch off main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
59 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
4 1048766 Carry out test as in the Table below
5 1048766 Meter reading value shall be less than 1 Megaohm
60 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
61 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Insulation resitance test
62 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
INSULATION RESISTANCE TEST BETWEEN CONDUCTORS AND OPPOSITE POLARITY
Polarity Testi Ensure that each fuse or single pole control and protection device is connected only in the phase
conductor
ii Intermediate contact of Edison screw lamp holder is connected to the phase conductor
iii Ensure that phase neutral and earth conductors at socket outlets are connected at the correct
terminals
iv Test Equipment ndash Multimeter (Ohm range) or Ohm meter
v Test Method
1 1048766 Switch off Main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in Figure 85
63 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
5 1048766 Test switches and single phase control devices at the phase conductors
6 1048766 Test socket outlet connection sources
7 1048766 Test Edison screw lamp holder connections
8 1048766 Meter reading value shall be less than 1 Ω
64 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Polarity test
65 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Earth Electrode Resistance Testi To test the earth electrode resistance
ii To ascertain the suitability of the location of the electrode
iii To ensure that the electrode is not buried within the resistance area of another electrode
iv Test equipment ndash Earth Resistance Tester
v Test method -
1 1048766 Terminal rsquoErsquo is connected to the electrode to be tested (green conductor)
2 1048766 Terminal lsquoPrsquo is connected to the potential spike (yellow conductor) at a distance of 10
meters from the earth electrode
3 1048766 Terminal lsquoCrsquo is connected to the current spike (red conductor) at a distance of 20 meters
from the earth electrode
Earth Electrode Resistance Measurement Method (Figure 86)
This test must be repeated at least three times to ensure that the reading is not affected by interacting
earthing regions
i Record the first reading (Z1) Example Z1 = 10 Ω
ii Move the voltage spike to a distance of 6 meters from the original position Record the second
reading (Z2 ) Example Z2 = 10 Ω
iii Move the voltage spike to a distance of 6 meters from the original position Record the third
reading (Z3) Example Z3 = 10 Ω
66 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Residual Current Device Testi Ensure that the residual current device (RCD) trips within the set time on the occurrence of current
leakage to earth
ii Test Equipment ndash RCD Tester RCCB Tester
iii Test Method 1
1 1048766 Use the Trip Test Button
2 1048766 Press the trip button found on the RCD to determine if it trips or otherwise This test would
not be able to determine the sensitivity of the RCD nor the time taken for it to trip
iv Test Method 2
i 1048766 Use a RCD Tester
ii This equipment is equipped with a 13A plug which can be connected to a 13A socket outlet
Select the RCD sensitivity to be the same as the sensitivity of the RCD to be tested to
determine if the RCD can trip The time to trip shall not exceed 40 mS
iii 1048766 Test method ndash
a) Position the selection switch in accordance with the sensitivity of the RCD used
Example 100 mA 01 A
b) Position the operations switch to lsquoNo Triprsquo (frac12 Rated mA = 50) connect the 3 pin plug to
the 13A socket outlet
67 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
c) Switch on the 13A socket outlet ndash ensure that the P-N and P-E lights light up
This shows that the polarity is correct (Note if both the lights as above do not light up the test cannot
be continued)
d) Press the test button ndash the reading shows less than 200 mS and simultaneously the lsquotestrsquo light lights
up and the P-N and P-E lights do not light up At that instant the RCD will not trip
e) Move the selection switch to 180o (+ve wave) ndash repeat steps (d) and (e) Move the operations
switch to lsquoTriprsquo (Rated mA = 100)
g) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200mS
h) Move the selection switch to 0o (-ve wave)
i) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
j) The above test is repeated until a near correct reading is obtained
k) Record the test results
l) Change the operations switch to lsquoFast Triprsquo and press the test button ndash RCD will trip within a
time not exceeding 40 millisecond
m) Repeat a number of times at 0o or 180o
On completion of a wiring installation a number of tests on the installation have to be conducted to
ascertain that the wiring circuits and connected appliances are safe for use Prior to carrying out the
tests an inspection has to be done the following tests shall be conducted
i Continuity Test
ii Insulation Resistance Test
iii Polarity Test
iv Earth Electrode Resistance test and
v Residual Current Device Test
821 Continuity Test
There are 3 main types of continuity tests for the final circuits-
i Protection Conductor Continuity Test
ii Final Ring Circuit Conductor Continuity Test
68 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
iii Live and Neutral Conductor Continuity Test
a) Protection Conductor Continuity Test
bull To ascertain that all protection conductors are connected in the correct and effective manner
bull Test equipment ndash Multimeter (Ohm range) or Ohm meter
bull Test Method
1 1048766 Ensure that the main switch RCD and MCB are open circuited (switched off) and all loads are
disconnected
2 1048766 Connected the test leads as in the Figure 81
3 1048766 The meter reading shall be less than 1 Ω
Final Ring Circuit Conductor Continuity Test
bull To ensure that all conductors around the ring circuit have continuity
bull Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
bull Test Method
1 1048766 Disconnect both the supply source live conductors from the MCB the neutral conductor
from the neutral terminals and the earth conductor from the earth terminal in the distribution
fuse box
2 1048766 Connect the test leads as in the Figure 82 (EE)
3 1048766 Repeat the procedure for (L-L) and (N-N)
4 1048766 The meter reading value shall be less than 1 ohm Figure 82 - Final Ring Circuit Conductor
Continuity Test Ohm Meter
Disconnect both the supply source cables from mcbfuse
Take readings at earth conductors of both sources and note resistance readings
Live and Neutral Conductor Continuity Test
1 To ensure that each conductor in the circuit has continuity
2 Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
3 Test Method
1 1048766 Switch off the Main switch RCD and MCB
2 1048766 Disconnect all loads
3 1048766 Switch on all switches in the circuit
4 1048766 Disconnect the fusesfinal circuit breakers and close the circuit
5 1048766 Carry out the test as shown in Figure 83
6 1048766 The meter reading value shall be less than 1 ohm Figure 83 - Live and Neutral
Conductor Continuity Test Ohm Meter
Insulation Resistance Test
69 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
i Ensure that there is no leakage current between phase conductors phase and neutral conductors and
phase conductor and earth
ii Test the strength of the cable insulation
iii Test Equipment ndash Insulation Resistance Tester Operating voltage is 250VDC or 500VDC
iv Test Method
1 1048766 Switch off main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in the Table below
5 1048766 Meter reading value shall be less than 1 Megaohm
Polarity Test
i Ensure that each fuse or single pole control and protection device is connected only in the phase
conductor
ii Intermediate contact of Edison screw lamp holder is connected to the phase conductor
iii Ensure that phase neutral and earth conductors at socket outlets are connected at the correct
terminals
iv Test Equipment ndash Multimeter (Ohm range) or Ohm meter
v Test Method
1 1048766 Switch off Main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in Figure 85
5 1048766 Test switches and single phase control devices at the phase conductors
6 1048766 Test socket outlet connection sources
7 1048766 Test Edison screw lamp holder connections
8 1048766 Meter reading value shall be less than 1 Ω
Earth Electrode Resistance Test
i To test the earth electrode resistance
70 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
ii To ascertain the suitability of the location of the electrode
iii To ensure that the electrode is not buried within the resistance area of another electrode
iv Test equipment ndash Earth Resistance Tester
v Test method -
1 1048766 Terminal rsquoErsquo is connected to the electrode to be tested (green conductor)
2 1048766 Terminal lsquoPrsquo is connected to the potential spike (yellow conductor) at a distance of 10
meters from the earth electrode
3 1048766 Terminal lsquoCrsquo is connected to the current spike (red conductor) at a distance of 20 meters
from the earth electrode E P C Electrode 10 meter 10 meter
Figure 86 ndash Earth Electrode Resistance Measurement Test Equipment
Earth Electrode Resistance Measurement Method (Figure 86)
This test must be repeated at least three times to ensure that the reading is not affected by interacting
earthing regions
i Record the first reading (Z1) Example Z1 = 10 Ω
ii Move the voltage spike to a distance of 6 meters from the original position Record the second
reading (Z2) Example Z2 = 10 Ω
iii Move the voltage spike to a distance of 6 meters from the original position Record the third
reading (Z3)
Example Z3 = 10 Ω
Residual Current Device Test
71 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
i Ensure that the residual current device (RCD) trips within the set time on the occurrence of current
leakage to earth
ii Test Equipment ndash RCD Tester RCCB Tester
iii Test Method 1
1 1048766 Use the Trip Test Button
2 1048766 Press the trip button found on the RCD to determine if it trips or otherwise This test would
not be able to determine the sensitivity of the RCD nor the time taken for it to trip
iv Test Method 2
1048766 Use a RCD Tester
This equipment is equipped with a 13A plug which can be connected to a 13A socket outlet Select the
RCD sensitivity to be the same as the sensitivity of the RCD to be tested to determine if the RCD can
trip The time to trip shall not exceed 40 mS
1048766 Test method ndash
a) Position the selection switch in accordance with the sensitivity of the RCD used
Example 100 mA 01 A
b) Position the operations switch to lsquoNo Triprsquo (frac12 Rated mA = 50) connect the 3 pin plug to
the 13A socket outlet
c) Switch on the 13A socket outlet ndash ensure that the P-N and P-E lights light up This shows that
the polarity is correct (Note if both the lights as above do not light up the test cannot be
continued)
d) Press the test button ndash the reading shows less than 200 millisecond and simultaneously the
lsquotestrsquo light lights up and the P-N and P-E lights do not light up At that instant the RCD will
not trip
e) Move the selection switch to 180o (+ve wave) ndash repeat steps (d) and (e) = 100)
f) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
g) Move the selection switch to 0o (-ve wave)
h) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
i) The above test is repeated until a near correct reading is obtained
j) Record the test results
k) Change the operations switch to lsquoFast Triprsquo and press the test button ndash RCD will trip within a
time not exceeding 40 mS
l) Repeat a number of times at 0o or 180o
72 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 9 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (DC)
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
73 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Start stop button 240Vac 5A 2
9 Filament lamp (Bulb ) 240Vac 40W 3
10 Overload Relay 415V 20A 3
11 Three phase induction motor 5 hp 3
12 Single phase step down transformer 2500VA 1
13 Single core PVC insulated Cable 1mm 2 As required
14 Single core PVC insulated Cable 25mm 2 As required
15 DIN rail 35 mm As required
16 PVC type Cable tray 50 mm x 50 mm As required
17 Cable ties 4 ldquo As required
18 Flexible wires 05 mm As required
19 PVC Connectors 5 A amp 20 A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the schematic
diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a optional exercise
i Simple DOL starter
ii Forward reverse DOL starter
iii Forward Reverse Dahlander motor
iv Three motors operated in sequence by DOL starter operated by manual push
button or time delay relay
74 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
a One loop per-cycle
b Continuous operation in a loop
c optional circuit design to represent the same task
v Only one out of three motors to be operated at a time (quiz)
4 Test the functionality of completed project
LESSON 10 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (AC)
75 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 1
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Lamp point 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
76 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
11 Overload Relay 415V 20A 3
12 Three phase induction
motor
5 hp 3
13 Single core PVC insulated
Cable
1mm 2 As required
14 Single core PVC insulated
Cable
25mm 2 As required
15 DIN rail 35 mm As required
16 PVC type Cable tray 50 mm x 50 mm As required
17 Cable ties 4 ldquo As required
18 Flexible wires 05 mm As required
19 PVC Connectors 5 A amp 20 A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the
schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram optional exercise
4 Simple DOL starter
5 Forward reverse DOL starter
6 Test the functionality of completed project
77 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 1
78 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
cm
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Indicating light 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
11 Overload Relay 415V 20A 3
12 Three phase induction motor 5 hp 3
13 Single phase step down
transformer
2500VA 1
14 Single core PVC insulated
Cable
1mm 2 As required
15 Single core PVC insulated
Cable
25mm 2 As required
16 DIN rail 35 mm As required
17 PVC type Cable tray 50 mm x 50 mm As required
18 Cable ties 4 ldquo As required
19 Flexible wires 05 mm As required
20 PVC Connectors 5 A amp 20 A 240 V As required
21 Single pole MCB 6A 240 V 1
22 Single pole MCB 2A 240 V 1
23 Triple pole MCB 20A 415 V 1
24 Mounting board 30 cm x 40 cm x 3
cm
1
25 Relay cw 11 pin socket 10 A 240 Vac 2
26 Time delay relay 10 A 240 Vac 3
27 Triple pole Contactor 20A 240Vac 3
28 Batten type Lamp holder 240Vac 10 A 3
29 Start stop button 240Vac 10A 2
30 Indicating light (Bulb ) 240Vac 25W 3
31 Overload Relay 415V 20A 1
32 Three phase dahlander type
induction motor
5 hp 1
33 Single phase step down
transformer
24024Vac
2500VA
1
79 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
34 Single core PVC insulated
Cable
1mm 2 As required
35 Single core PVC insulated
Cable
25mm 2 As required
36 DIN rail 35 mm As required
37 PVC type Cable tray 50 mm x 50 mm As required
38 Cable ties 4 ldquo As required
39 Flexible wires 075 mm As required
40 PVC Connectors 5 A amp 20 A 240 V As required
41 Terminal block 20A 240Vac As required
Procedures
5 Identify each component according to specification and quantity required from the schematic
diagram attached
6 Test the functionality of each component by using multi-meter or power supply whichever
applicable
7 Wire component according to circuit diagram
8 Three motors operated in sequence by DOL starter operated by manual push button or time
delay relay
a One loop per-cycle
b Continuous operation in a loop
c optional circuit design to represent the same task
d Only one out of three motors to be operated at a time (quiz)
9 Test the functionality of completed project
80 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
BASIC DESIGN INDUSTRIAL MOTOR CONTROL (SEQUENCE CONTROL)
THREE PHASE INDUCTION MOTOR OPERATED IN SEQUENCE BY DIRECT ON LINE
STARTER
LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
81 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
82 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Lcd lamp indicator 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
11 Overload Relay 415V 20A 3
12 Three phase induction motor 5 hp 3
13 Single phase step down transformer 2500VA 1
14 Single core PVC insulated Cable 1mm 2 As required
15 Single core PVC insulated Cable 25mm 2 As required
16 DIN rail 35 mm As required
17 PVC type Cable tray 50 mm x 50 mm As required
18 Cable ties 4 ldquo As required
19 Flexible wires 1 mm Oslash As required
20 PVC Terminal block 10A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the schematic
diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a optional exercise
i Forward Reverse dahlander motor
4 Test the functionality of completed project
83 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
THREE PHASE DAHLANDER TYPE INDUCTION MOTOR OPERATED FORWARD AND
REVERSE OPERATION BY DIRECT ON LINE STARTER
84 ndash 99EASYTECH ENTERPRISE
LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
Introduction
If a motors windings are connected in the star configuration any two phases will be in series across
the supply and hence the line current will be smaller(by 577) than if the windings were connected in
the delta arrangement
Hence larger-type motors with heavy starting currents are first connected in star and then when the
starting currents fall in delta This of course means that all six of the ends of the windings must be
brought to terminations outside the casing (Fig 833)
EZTECH
EZTECH ELECTRICAL INSTALLATION GUIDE
The automatic version of this starter incorporates a timing relay which automatically changes the
connections from star to delta Figs 834 and 835 show the wiring and schematic diagrams for a star
delta starter
Objectives
1 Identify component and the specification
2 Design forward reverse star delta starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
2 ndash 99EASYTECH ENTERPRISE
REV -C
LEGENDMCCB Moulded Case Circuit BreakerTOR Thermal Over Load RelayFOW-C Mains Forward ContactorREV-C Mains Reverse ContactorDC Delta ContactorSC Star ContactorS-SW Mains Selector Switch
SC
V2
W2
U2
DC
V1
W1
U1
TOR
TOR
FOW-C
30A MCCB
TOR
MAIN CIRCUIT FORWARD REVERSE STAR DELTA
RYBN S
-SW
3 PHASEINDUCTION MOTOR
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Relay 10 A 240V 3
5 Triple pole Contactor
6 cw NO NC auxiliary contact
240Vac 20 A 4
7 Overload Relay 415 V 1
8 LED indicator 240vac 5 A 4
9 Start stop button 240Vac 5A 2
10 DIN rail 35 mm As required
11 Flexible wires 1 mm As required
12 Single core PVC insulated
wire
25 mm As required
13 Terminal block 20 A As required
14 Squirrel cage motor 5kW 1
15 5 pin plug and socket 415V 20A 1
16 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
3 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
a Manual star delta
b Manual Forward reverse star delta starter
c Automatic star delta starter
d Automatic Forward reverse star delta starter
4 Test the functionality of completed project
4 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
Objectives
1 Identify component and the specification
2 Design auto transformer starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
5 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Autotransformer starter is used to start a 3 phase induction motor that has a rating between 10 to 15 hp
6 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Autotransformer set 10Kw 415 V 50 Hz 1
5 Triple pole Contactor 240Vac 4
6 Batten type Lamp holder 240 Vac 105 A 4
7 Start stop button 240Vac 10A 4
8 Filament lamp (Bulb ) 240Vac 40W 4
9 DIN rail 35 mm As required
10 Flexible wires 1 mm As required
7 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
11 Single core PVC insulated
wire
25 mm As required
12 Terminal block 20 A As required
13 Squirrel cage motor 10kW 1
14 5 pin plug and socket 415V 20A 1
15 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a open transient autotransformer starter
b close transient autotransformer starter
c Forward reverse autotransformer starter
4 Test the functionality of completed project
8 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
Objectives
1 Identify component and the specification
2 Design rotor resistance starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
9 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Rotor Resistor set 10kW 1
5 Triple pole Contactor 240Vac 20A 4
6 Indicating light 240vac 5 A 4
7 Start stop push button 240Vac 5A 4
8 DIN rail 35 mm As required
9 Flexible wires 1 mm 2 As required
10 Single core PVC insulated wire 25 mm 2 As required
11 Terminal block 20 A As required
12 Slip Ring motor 10kW 1
13 5 pin round 3 phase socket 415V 20A 1
14 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
10 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
4 Test the functionality of completed project
a Dead circuit test b Life circuit test
5 Measure starting and running Amps
LESSON 16
TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
An installation in general will suffer damage
Damage usually occurs on the electric motor control as follows
1 Damage to the main circuit
2 Damage to the control circuit
The cause of the damage
i Overcurrent overload short circuit
ii Leakage current to ground
iii Equipment malfunction
iv The main control circuit
a Trip of main circuit protection devices fire
b Defect of motor terminal such as short circuit fire loose
v The control circuit is not functioning -
a contactor relay relay time overload relay does not work damaged burned
b Loose cable connection disconnected
Detecting and Repairing Damage
Examples of damage are as follows
i Motor does not work
ii Motor function and overload relay trips
iii Motor function but only partially functional control circuit
Methods of detecting damage
Among the known methods necessary to detect damage are as follows
1 Turn off the electricity at the main switch (main switch) in order to avoid any danger during the
work carried out to detect damage
2 Check all the protective gear that controls the motor control main circuit
11 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
3 Make sure the damage function control circuit
4 Check the control circuit according to the schematic circuit diagram of the motor control
5 Check the operation of the control circuit
Note
Use wiring that has been installed on the SYSTEM OF MOTOR CONTROL BOARD by Forward
Reverse control circuit for Star Delta to test and look for damage
SELF-ASSESSMENT QUESTIONS
1 (a) Explain what is meant by the term lsquoback emfrsquo in a motor
(b) Outline the basic differences between series shunt and compound wound dc motors
2 (a) With the aid of diagrams explain how the speed of series shunt and compound-wound motors
may be controlled
(b) A 440V dc shunt-wound motor has a field resistance of 200R and an armature resistance of 06 R
When its speed is 20 rev d second the current drawn from the supply is 122A Calculate its back
emf at this speed If the speed were decreased to 19 revssecond the field flux remaining unchanged
calculate the new back emf and the new armature current
3 A load of 64 kW at 240 V is supplied from the terminals of a shunt-wound dc generator The field
resistance is 180 A Calculate the armature current
4 (a) Explain with the aid of a diagram how a rotating magnetic field may be
(b) What is meant by lsquosynchronous speedrsquo
Calculate the synchronous obtained speed of a 12 pole motor if the supply frequency is 50Hz
5 (a) Explain the action of a synchronous motor
(b) What methods are available to start a synchronous motor Explain with diagrams
6 (a) Explain the action of a cage induction motor
(b) What is meant by the term lsquosliprsquo
Calculate the percentage slip of a six pole induction motor running at 162 revssecond from a 50 Hz
supply
7 Describe with sketches three different ways of starting a single-phase induction motor
12 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
8 Explain with the aid of a sketch the action of a three-phase DOL starter
What are dashpots used for How are remote start and stop buttons connected
9 A I0 kW 240V 50Hz single-phase cage rotor induction motor is 85efficient and has a PF of 068
lagging Calculate the motor current and the value of capacitor required to raise the PF to 093
lagging
10 Calculate the torque developed by an 18 kW four-pole induction motor run at 35 slip from a
50Hz supply
APPENDIX 1
13 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 11
14 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 111
Attachment Reference
httpswwwtlc-directcoukBook621htm
httpwwwstgovmyindexphpms
15 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 3ndash WIRING SYSTEM OF SINGLE PHASE POWER CIRCUIT33
LESSON 4ndash CONDUIT BENDING AND TRUNKING FABRICATION TECHNIQUE37
LESSON 5 ndashWIRING SYSTEM OF 1 Oslash LIGHTING AND POWER CIRCUIT42
POWER CIRCUITS42
LESSON 6 ndash WIRING SYSTEM OF 3 Oslash DISTRIBUTION BOARD45
LESSON 7 ndash WIRING SYSTEM OF THREE PHASE LIGHTING AND POWER CIRCUIT52
LESSON 8 INSPECTION AND TESTING OF ELECTRICAL INSTALLATION55
CONTINUITY TEST60
Polarity Test64
Earth Electrode Resistance Test67
Earth Electrode Resistance Measurement Method (Figure 86)67
Residual Current Device Test68
LESSON 9 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (DC)74
LESSON 10 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (AC)76
LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE79
LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER83
LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER1
LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER4
LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER8
a Dead circuit test10
b Life circuit test10
LESSON 1610
TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR10
SELF-ASSESSMENT QUESTIONS11
Electricity Supply Act 1990Electricity Regulations 1994MS IEC 603642003 Standard Electrical Installations of BuildingsMS 19362006 Standard Electrical Installations of Buildings ndash Guide To MS IEC 60364 andMS 19792007 Standard Electrical Installation of Buildings ndash Code of Practice
3 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
ELECTRICITY SUPPLY SPECIFICATIONS
Electricity supply for domestic consumers according to MS IEC 60038 standards meets the
following specifications -
i Single phase supply with nominal voltage of 230V range +10 -6
ii Three phase supply with nominal voltage of 400V range +10 -6
iii Permitted frequency is 50Hz + 1
iv Earthing system type (TT System) as in Figure 21 and Figure 22
4 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Legal Requirements
Regulation 11(1) of the Electricity Regulations 1994 states that all wiring or rewiring of an
installation or extension to an existing installation which shall be carried out by an Electrical
Contractor or a Private Wiring Unit have to obtain the approval in writing from a licensee or supply
authority
1 Planning of Electrical Wiring Work
Prior to carrying out wiring work the wiremancontractor should plan and determine the tasks to be
undertaken so that the work carried out is tidy neat and safe to be used The wiremancontractor shall
-i Undertake a site visit
5 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
ii Determine the consumer load requirements
iii Calculate the maximum load demand and
iv Submit the plans drawings and specifications
The planning flow chart for building wiring installations is as shown in Figure 31
11 Site Visit
The purpose of the site visit is to determine -
i Electrical equipment suitable for use
ii Maximum load demand
iii Single or three phase incoming supply
iv Type of wiring and Equipment arrangement
Determining Consumer Load RequirementsWith the aid of the building floor plans the installation requirements such as the proposed load
placement of electrical equipment and installation design plans can be determined
11 Calculating Maximum Load Demand
The estimate of the maximum load demand is for determining the specifications of the wiring
equipment such as the cables and plans
According to clause 311 of MS IEC 60364 Part 1 to determine the maximum demand for each circuit
while ensuring an economic and reliable design within the permitted voltage drop limits Diversity
factors may be taken into account The maximum current demand calculations for each circuit must be
prepared These details will show the current requirements in amperes for each phase and also assist
in determining the cable sizes
Refer to the Third Schedule (Table A and Table B) and Regulation 11(2) of the Electricity Regulations
1994 to estimate the maximum current demand and the diversity factors that may be used for domestic
installations
12 Submission of the Plans Drawings and Specifications Regulation 65 of the Electricity
Regulations 1994 states that the eligibility to submit plans is as follows -
i Wireman with Single Phase Restriction ndash Low voltage single phase up to 60 A
ii Wireman with Three Phase Restriction ndash Low voltage up to 60A
6 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
2 CONTROL AND PROTECTION SYSTEM FOR ELECTRICAL WIRING
7 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
8 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
21 Selection of Control and Protection System for Electrical Wiring
Control and protection of a wiring is a system of separationisolation and switching together with the
protection system which are needed in every domestic wiring installation
22 Isolation and Switching
Examples of isolation and switching are switches power plugs socket outlets and circuit breakers
Their function is to manually connect and break the supply in a particular circuit without interfering
with other circuits
They also aim to prevent the danger of electrical shocks during maintenance testing fault finding and
repair works
23 Protection
This provides protection from dangers caused by electrical currents such as over current earth
leakage current short circuit lightning etc to the wiring system electrical equipment or consumer
The circuit below shows the isolation and protection devices which must be installed in a domestic
electrical wiring system
1 Current Protection
In general protection from the dangers of current can be divided into two aspects namely
i Overcurrent Protection (Over Load or Short Circuit) Properly rated circuit breakers or fuses suitable
for over load or short circuit protection must be used
9 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
The circuit breakers or fuses must be installed on the live conductors only For three phase circuits all
the circuit breakers or fuses must be combined in one set of circuits
Selection of over current devices must be based on the short circuit fault current levels of the circuit
breaker or main switch (kA)
ii Earth Leakage Current Protection
Properly rated Residual Current Devices (RCD) must be used for protection from earth leakage
currents (to prevent electric shocks)
a) Regulation 36(1) of the Electricity Regulations 1994 states that for a place of public entertainment
protection against earth leakage current must be provided by a residual current device of sensitivity
not exceeding 10 mA
b) Regulation 36(2) of the Electricity Regulations 1994 states that for a place where the floor is likely
to be wet or where the wall or enclosure is of low electrical resistance protection against earth leakage
current must be provided by a residual current device of sensitivity not exceeding 10 mA
c) Regulation 36(3) of the Electricity Regulations 1994 states that for an installation where hand-held
equipment apparatus or appliance is likely to be used protection against earth leakage current must be
provided by a residual current device of sensitivity not exceeding 30 mA and
d) Regulation 36(4) of the Electricity Regulations 1994 states that for an installation other than the
installation in (a) (b) and (c) protection against earth leakage current must be provided by a residual
current device of sensitivity not exceeding 100 mA
CABLE SELECTION
31 Selection of Wiring Cable Type
The selection of the cable size has to take into consideration the following-
i All wiring cables must be PVC or PVCPVC insulated with copper conductors Conductors with
cross sectional areas of 16mm2 or less must be of copper Aluminium conductors are not permitted
Refer to Table 4D1A in Appendix II for the current carrying capacities of copper conductor
ii Cables for swimming pools must be water resistant PE (polyethylene) insulated
10 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
iii The selected cable must be capable of delivering the electrical energy efficiently
iv The cable size allows it to carry the current without heating the cable
v The voltage drop must not exceed 4 of the supply voltage Refer to Table 4D1B in Appendix III
vi The cable insulation must be suitable for the surrounding conditions of the installation such as the
ability to withstand the surrounding temperatures and the ability to provide mechanical protection
vii Each conductor in the installation must be protected from overcurrent by means of overcurrent
protection devices needed to prevent damage to the cable insulation
32 Factors Related to Cable Current Carrying CapacityThe following factors in relation to the current carrying capacity of cables must be taken into
consideration-
i Surface wiring using clips ndash group factor
ii Wiring using conduits ndash space factor 40
iii Wiring using ducts ndash space factor 45
iv Concealed wiring ndash group factor and
v Concealed wiring using ducts ndash surrounding temperature factor
Use of Minimum Cross Sectional Area Rating of Wiring ConductorsThe following are the minimum cross sectional areas of conductors based on their applications-
Use of Protection Conductor Minimum Cross Sectional Area Rating
In Comparison with Phase Conductor Cross Sectional Area
The following table shows the protection conductor minimum cross sectional area in comparison
with the phase conductor cross sectional area
Functions and Colour Identification of Non Flexible Cables
The following table shows the functions and colour identification of non flexible cables
11 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
33 Use of Minimum Cross Sectional Area Rating of Wiring Conductors
The following are the minimum cross sectional areas of conductors based on their applications-
34 Use of Protection Conductor Minimum Cross Sectional Area Rating
In Comparison with Phase Conductor Cross Sectional Area
The following table shows the protection conductor minimum cross sectional area in comparison
with the phase conductor cross sectional area
Use of Minimum Cross Sectional Area Rating of Wiring Conductors
The following are the minimum cross sectional areas of conductors based on their applications-
Use of Protection Conductor Minimum Cross Sectional Area Rating
In Comparison with Phase Conductor Cross Sectional Area
The following table shows the protection conductor minimum cross sectional area in comparison
with the phase conductor cross sectional area
Functions and Colour Identification of Non Flexible CablesThe following table shows the functions and colour identification of non flexible cables
12 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Flexible Cables
i Flexible cables of cross sectional area less than 40 mm2 are used in installations for electrical
accessories such as ceiling roses lamp fixtures or attachments socket plugs for mobile
appliances etc
ii Flexible cables shall not be used for permanent wiring
iii Flexible cables for the permanent use of electrical appliances should not exceed 3 meters in
length
37 Functions and Colour Identification of Flexible Cables
Conductor Insulation and Types of WiringVarious material and insulation layers are used for conductor protection Cable selection in
accordance to insulation layers must be done correctly for the type of the wiring installation as
shown in the table below
Functions and Colour Identification of Non Flexible CablesThe following table shows the functions and colour identification of non flexible cables
3 SELECTION OF WIRING ACCESSORIES
i All wiring accessories to be used have to be of those approved by the Energy Commission and
labeled with labels issued by SIRIM For all wiring using UPVC conduits -
13 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
a) Switches socket outlets 3 pin plugs ceiling roses connectors sockets ndash construction material shall
be of polycarbonate type
iii For all wiring using metal conduits - Switches socket outlets and connectors ndash construction
material shall be of metal clad type and All accessories shall be effectively earthed
iv Switch fuse used in single phase installations shall have the fuse permanently connected and not
move with the fuse
v Fuse switch used in 3 phase domestic installations also has fuse and switch The fuse connector is
installed together to allow the fuse to move simultaneously with the switch
vi Lamp
a) Fluorescent lamps using magnetic ballasts (watt loss not exceeding 6 watts) shall be
equipped with dry paper type capacitor
b) Fluorescent lamps using electronic ballasts or high frequency electronic ballasts do not
need capacitors
c) Outdoor domestic lamp installations shall use weather proof and water proof lamps
d) Submerged light installations (example in swimming pools fountains etc) shall have water
proof lamps with a voltage not exceeding 12 Volt AC
vii Electric water heaters is divided into 2 types namely
1 instantaneous water heaters and
2 stored water heaters (storage tank type)
a) Instantaneous water heaters shall be equipped with a 2 pole control switch and its own
residual current device
b) Storage water heaters (storage tank type) shall be installed with an
Water heaters exceeding 3kW shall be permanently connected to a 20A30A rated circuit
breakerfuse with an isolator switch and residual current device
viii Electric cookers exceeding 3kW shall have its own circuit connected permanently to a 30A rated
circuit breaker or fuse with an isolator switch and cooker control unit incorporated with a 13A socket
outlet Two or more cooker appliances may be installed in the same room within a distance of 2
meters
ix Electric motors (fence gate air conditioners fountains swimming pools fish ponds water
pumps) exceeding 373W but not exceeding 2238W shall be connected permanently to a 20A30A
rated circuit breakerfuse together with an isolator motor starter and 15A socket outlet
14 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
The motor starter shall be of Direct-On-Line type with the appliance together with the contactor
overload relay and on-off control The circuit breakerfuse which controls the motor circuit shall be
capable of withstanding the starting current of the motor
x Electric bells ndash the circuit shall have a push button switch and a ACDC transformer
xi Ceiling fans shall conform to clause 21101 of the MS 12192002 standard with regards to test on
the suspension system of ceiling fans
EARTHING OF ELECTRICAL INSTALLATIONS51 Earthing
Earthing is a connection system between the metallic parts of an electrical wiring system and the
general mass of the earth This will provide an easy path with a low impedence or resistance to earth to
enable the protection system to operate effectively It will thus ensure safety to human
beingsconsumers from the dangers of electric shocks if earth leakage currents are present In general
an electrical installation is earthed because of -
i Safety reasons
ii Protection system requirements
iii Need to limit over voltages
iv Need to provide a path for electrical discharge
v Legal requirements
52 Classification of Earthing
Generally earthing can be divided into 2 parts namely -
i System Earthing
a To isolate the system under fault conditions
b To limit the potential difference between conductors which are not insulated in an area
c To limit the occurrence of over voltages under various conditions
ii Equipment Earthing
Equipment earthing is undertaken to protect human beingsconsumers If a live source comes into
contact with the equipment body electrical energy will flow to the earth without flowing through the
human being consumerrsquos body This is because of the fact that the human body has a greater
resistance compared with the resistance to earth
53 Types and Functions of Earthing Accessories
Earthing accessories are as follows -
i Earthing Electrode
Copper jacketed steel core rods are used as electrodes for domestic wiring
ii Equipotential Bonding
15 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
This is the conductor which is connected between the consumer earthing point and the exposed
metallic part The minimum cable size for this purpose is 10 mm2
iii Protection Conductor
This is the conductor which connects the consumer earthing point with other parts of the installation
which needs earthing Its size is as follows-
a) Same size as the phase cable up to a size of 16mm2
b) 16 mm2 if the phase cable size is between 16 mm2 and 35 mm2
c) Half the size of the phase cable if the size of the phase cable exceeds 35 mm2
54 Earthing Arrangements Using a TT System
i The first alphabet indicates the earthing arrangements from the supply side
ii The second alphabet indicates the earthing arrangement in the consumerrsquos installation
T ndash first Indicates that the supply system has its own earthing arrangements
T ndash second Indicates that all metallic frames of the electrical appliances etc are connected directly to
earth
Parts that are Required to be Earthed
i All metallic structures in the wiring system (non current carrying) such as metallic covers conduits
ducts the armour of catenary wires etc
ii A secondary winding point in a transformer and
iii Frame of metal roof truss
56 Parts that are not Required to be Earthed
i Short isolated metallic parts for mechanical protection of cables which have non metallic sheaths
other than conduits which are connected at entry points between the building and conduits which
protect discharge lamp cables
ii Cable clips for installing cables
iii Metallic covers for lamps
16 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
iv Small metallic parts such as screws and name plates which are isolated by means of insulation
v Metallic lamp parts for filament lamps in water proof floors
57 Termination to Earth
The termination to earth is done as shown in Figure 72
Earth Electrode Resistance
The maximum permitted earth electrode resistance for different types of installations is as shown in
the Table below
Earth electrode for installations protected by RCDs of sensitivity 100mA 10 Ω
Lightning arrestor earth electrode 10 Ω
Legal Requirements
i Sub regulation 12(1) and 12(2) of the Electricity Regulations 1994 state that any electrical wiring in
an installation shall be under the immediate supervision of a Wireman with Single Phase Restriction or
Three Phase Restriction Upon completion the Wireman shall certify a Supervision and Completion
Certificate
ii Sub regulation 13(1) and 13 (2) of the Electricity Regulations 1994 state that the installation shall
be tested by a Wireman with Single Phase Restriction or a Wireman with Three Phase Restriction
authorized to test any installation and who shall certify a Test Certificate for the installation
iii Sub regulation 14(1) of the Electricity Regulations 1994 states that the Supervision and
Completion Certificate and the Test Certificate as in regulations 12 and 13 shall be in Forms G and H
respectively as prescribed in the First Schedule
17 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
4 SAFETY REQUIREMENTS FOR ELECTRICAL WIRING WORKS IN RESIDENTIAL BUILDINGS
61 Safety Requirements
Safety requirements for electrical wiring works have to be followed to eliminate any accidents which
can result in physical damage or loss of life or property Failure to meet the safety regulations may
result in workers consumers or the public being inflicted with electrical shocks
In addition to this safety steps will also encourage workers or electricity consumers who are
disciplined and who always give importance to safety
62 Safety Steps
Safety requirements have to be followed whenever electrical works are undertaken in a residential
building
i Personal Safety
a Use suitable personal protection equipment as needed such as safety shoes gloves safety helmet
etc when at the work place
b Use safety clothing suitable for the work to be undertaken
c Do not wear jewellery or decorative items such as rings watches chains etc while carrying out
electrical works
ii Safety at the Work Place
a Acquire knowledge about the dangers of electrical works that is to be undertaken and how to deal
with those dangers
b Always adhere to the safety regulations which have been set for the work place
c Ensure that the electricity supply is switched off before carrying out the works
d Acquire the needed knowledge and practice a cautious and calm attitude while working ensure
cleanliness in and around fellow workers
e While working at elevated places the worker should always use suitable equipment such as wooden
or aluminium ladders iron scaffoldings or platforms safety belts or other equipment needed to ensure
that the work can be undertaken safely
f Use electrical equipment which is operational and safe to be used and ensure that the supply for it is
being supplied through a residual current device (RCD) with a sensitivity of 30 mA
g Ensure that exposed temporary supply electrical cables have mechanical protection
h If inflammable or corrosive material is present necessary safety steps have to be undertaken as
required by the relevant safety regulations
63 Dangers of Electrical Shocks
i Electrical Shock
Electrical shocks can occur due to direct or indirect contact
a Direct Contact
18 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Direct contact occurs when the worker or consumer receives an electrical shock on touching directly a
live conductor or cable
b Indirect Contact
Here the electric shock occurs due to contact with a part which is connected to the electrical
installation and not to a direct contact with a live cable or conductor possibly due to damages in the
appliance or insulation resulting in leakages of current
Why Electric Shocks Occura Unsafe Work Method or Action Undertaking Electrical Work Without Disconnecting the
Supply
Maintenance or circuit testing work done without disconnecting the supply will have a high possibility
of electrical shocks occurring
bull Not Following Safe Work Procedures
To eliminate the occurrence of electrical shocks each worker has to always follow safe work
procedures which are set by regulations and standards
b Defects in the Electrical System
i Leakage Current
Leakage currents or earth leakage currents can result in the metallic frames becoming live and
energised This can give rise to the danger of electrical shock to the worker consumer or the public if
they hold or come into contact with the metallic frame
ii Exposed Conductor or Disconnected Cable
Exposed conductors or cables which are broken and are alive (energised) can result in electrical shock
when touched The supply source must be immediately isolated or switched off and a report must be
made to the responsible entity
64 First Aid and Basic Pulmonary Resuscitation
i First Aid
First aid is the initial assistance given to a person who has met with an accident is sick or is injured to
prevent the condition of the victim from becoming more serious while awaiting the arrival of the
paramedics (ambulance) or before being brought to the hospital
i Pulmonary Resuscitation
Pulmonary resuscitation has to be undertaken to assist the victim who has breathing difficulties as a
result of being drowned receiving an electrical shock etc Pulmonary resuscitation has to be carried
out in accordance to the correct method as stated in the first aid manuals issued by accredited first aid
bodies
ii First Aid Box
19 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
A first aid box has to be provided by the building owner construction site supervisor or brought
personally by the worker under the supervision of the responsible person
65 Training Programme
The management shall conduct periodic training programmes for the workers with regards to work
safety on aspects including the following -
i Dangers of electrical work being undertaken and how to control those dangers
ii The safety regulations set for the work place and
iii First aid procedures
66 Fire Prevention
Fire Extinguisher A suitable functioning fire extinguisher to control fires has to be made available at
the work place at all times
67 Competent Person
The Electricity Regulations 1994 require that all electrical work has to be undertaken by or under the
direct supervision of a competent person registered with the Energy Commission Besides that the
electrical contractor undertaking the electrical work has also to be registered with the Energy
Commission The installation owner thus has to ensure that the appointed electrical contractor is
registered with the Energy Commission and that the registration is still valid
INSTALLATION CIRCUITS AND SYSTEMS1 Block diagrams
These show using squares rectangles etc the sequence of a system without too much technical detail
eg Figures 1517 and 1526
2 Layout diagrams
These are very similar to block diagrams but they indicate more technical detail and tend to show
items in their correct geographical location (eg Figures 1518 and 1519)
3 Circuitschematic
These show how a circuit functions and takes no account of exact locations of terminals or equipment
(eg Figures 1528 1529 1532 1534 etc)
4 Wiring diagram
These indicate how a circuit or system is physically wired (eg Figures 152 154 156 etc)
Most induction motors are started directly on line but when very large motors are started that way
they cause a disturbance of voltage on the supply lines due to large starting current surges To limit the
starting current surge large induction motors are started at reduced voltage and then have full supply
voltage reconnected when they run up to near rotated speed Two methods are used for reduction of
starting voltage are star delta starting and auto transformer stating
20 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Working Principal of Star-Delta Starter
This is the reduced voltage starting method Voltage reduction during star-delta starting is achieved by
physically reconfiguring the motor windings as illustrated in the figure below During starting the
motor windings are connected in star configuration and this reduces the voltage across each winding 3
This also reduces the torque by a factor of three After a period of time the winding are reconfigured as
delta and the motor runs normally
StarDelta starters are probably the most common reduced voltage starters They are used in
an attempt to reduce the start current applied to the motor during start as a means of reducing the
disturbances and interference on the electrical supply
Traditionally in many supply regions there has been a requirement to fit a reduced voltage
starter on all motors greater than 5HP (4KW) The StarDelta (or WyeDelta) starter is one of the
lowest cost electromechanical reduced voltage starters that can be applied
The StarDelta starter is manufactured from three contactors a timer and a thermal overload
The contactors are smaller than the single contactor used in a Direct on Line starter as they are
controlling winding currents only The currents through the winding are 1root 3 (58) of the
current in the line
There are two contactors that are close during run often referred to as the main contractor and
the delta contactor These are AC3 rated at 58 of the current rating of the motor The third
contactor is the star contactor and that only carries star current while the motor is connected in star
The current in star is one third of the current in delta so this contactor can be AC3 rated at one
third (33) of the motor rating
Star-delta Starter Consists following units
1) Contactors (Main star and delta contactors) 3 Norsquos (For Open State Starter) or 4 Norsquos (Close
Transient Starter)
2) Time relay (pull-in delayed) 1 No
3) Three-pole thermal over current release 1No
4) Fuse elements or automatic cut-outs for the main circuit 3 Nos
5) Fuse element or automatic cut-out for the control circuit 1No
Power Circuit of Star Delta Starter
1 The main circuit breaker serves as the main power supply switch that supplies electricity to the
power circuit
2 The main contactor connects the reference source voltage R Y B to the primary terminal of the
motor U1 V1 W1
21 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
3 In operation the Main Contactor (KM3) and the Star Contactor (KM1) are closed initially and
then after a period of time the star contactor is opened and then the delta contactor (KM2) is
closed The control of the contactors is by the timer (K1T) built into the starter The Star and Delta
are electrically interlocked and preferably mechanically interlocked as well In effect there are
four states
4 The star contactor serves to initially short the secondary terminal of the motor U2 V2 W2 for the
start sequence during the initial run of the motor from standstill This provides one third of DOL
current to the motor thus reducing the high inrush current inherent with large capacity motors at
startup
5 Controlling the interchanging star connection and delta connection of an AC induction motor is
achieved by means of a star delta or wye delta control circuit The control circuit consists of push
button switches auxiliary contacts and a timer
Control Circuit of Star-Delta Starter (Open Transition)
1 The ON push button starts the circuit by initially energizing Star Contactor Coil (KM1) of star
circuit and Timer Coil (KT) circuit
2 When Star Contactor Coil (KM1) energized Star Main and Auxiliary contactor change its
position from NO to NC
3 When Star Auxiliary Contactor (1)( which is placed on Main Contactor coil circuit )became
NO to NC itrsquos complete The Circuit of Main contactor Coil (KM3) so Main Contactor Coil
energized and Main Contactorrsquos Main and Auxiliary Contactor Change its Position from NO
To NC This sequence happens in a friction of time
4 After pushing the ON push button switch the auxiliary contact of the main contactor coil (2)
which is connected in parallel across the ON push button will become NO to NC thereby
providing a latch to hold the main contactor coil activated which eventually maintains the
control circuit active even after releasing the ON push button switch
5 When Star Main Contactor (KM1) close its connect Motor connects on STAR and itrsquos
connected in STAR until Time Delay Auxiliary contact KT (3) become NC to NO
6 Once the time delay is reached its specified Time the timerrsquos auxiliary contacts (KT)(3) in
Star Coil circuit will change its position from NC to NO and at the Same Time Auxiliary
contactor (KT) in Delta Coil Circuit(4) change its Position from NO To NC so Delta coil
energized and Delta Main Contactor becomes NO To NC Now Motor terminal connection
change from star to delta connection
7 A normally close auxiliary contact from both star and delta contactors (5amp6)are also placed
opposite of both star and delta contactor coils these interlock contacts serves as safety
switches to prevent simultaneous activation of both star and delta contactor coils so that one
22 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
cannot be activated without the other deactivated first Thus the delta contactor coil cannot be
active when the star contactor coil is active and similarly the star contactor coil cannot also
be active while the delta contactor coil is active
8 The control circuit above also provides two interrupting contacts to shutdown the motor
The OFF push button switch break the control circuit and the motor when necessary The
thermal overload contact is a protective device which automatically opens the STOP Control
circuit in case when motor overload current is detected by the thermal overload relay this is to
prevent burning of the motor in case of excessive load beyond the rated capacity of the motor
is detected by the thermal overload relay
9 At some point during starting it is necessary to change from a star connected winding to a
delta connected winding Power and control circuits can be arranged to this in one of two
ways ndash open transition or closed transition
What is Open or Closed Transition Starting
(1) Open Transition Starters
Discuss mention above is called open transition switching because there is an open state between
the star state and the delta state
In open transition the power is disconnected from the motor while the winding are reconfigured via
external switching
When a motor is driven by the supply either at full speed or at part speed there is a rotating
magnetic field in the stator This field is rotating at line frequency The flux from the stator field
induces a current in the rotor and this in turn results in a rotor magnetic field
When the motor is disconnected from the supply (open transition) there is a spinning rotor within
the stator and the rotor has a magnetic field Due to the low impedance of the rotor circuit the time
constant is quite long and the action of the spinning rotor field within the stator is that of a
generator which generates voltage at a frequency determined by the speed of the rotor When the
motor is reconnected to the supply it is reclosing onto an unsynchronized generator and this result
in a very high current and torque transient The magnitude of the transient is dependent on the
phase relationship between the generated voltage and the line voltage at the point of closure can
be much higher than DOL current and torque and can result in electrical and mechanical damage
Open transition starting is the easiest to implement in terms or cost and circuitry and if the timing
of the changeover is good this method can work well In practice though it is difficult to set the
necessary timing to operate correctly and disconnectionreconnection of the supply can cause
significant voltagecurrent transients
In Open transition there are Four states
23 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 OFF State All Contactors are open
2 Star State The Main [KM3] and the Star [KM1] contactors are closed and the delta [KM2]
contactor is open The motor is connected in star and will produce one third of DOL torque at one
third of DOL current
3 Open State This type of operation is called open transition switching because there is an
open state between the star state and the delta state The Main contractor is closed and the Delta
and Star contactors are open There is voltage on one end of the motor windings but the other end
is open so no current can flow The motor has a spinning rotor and behaves like a generator
4 Delta State The Main and the Delta contactors are closed The Star contactor is open The
motor is connected to full line voltage and full power and torque are available
(2) Closed Transition StarDelta Starter
There is a technique to reduce the magnitude of the switching transients This requires the use of a
fourth contactor and a set of three resistors The resistors must be sized such that considerable
current is able to flow in the motor windings while they are in circuit
The auxiliary contactor and resistors are connected across the delta contactor In operation just
before the star contactor opens the auxiliary contactor closes resulting in current flow via the
resistors into the star connection Once the star contactor opens current is able to flow round
through the motor windings to the supply via the resistors These resistors are then shorted by the
delta contactor If the resistance of the resistors is too high they will not swamp the voltage
generated by the motor and will serve no purpose
In closed transition the power is maintained to the motor at all time This is achieved by
introducing resistors to take up the current flow during the winding changeover A fourth
contractor is required to place the resistor in circuit before opening the star contactor and then
removing the resistors once the delta contactor is closed These resistors need to be sized to carry
the motor current In addition to requiring more switching devices the control circuit is more
complicated due to the need to carry out resistor switching
In Close transition there are Four states
1 OFF State All Contactors are open
2 Star State The Main [KM3] and the Star [KM1] contactors are closed and the delta [KM2]
contactor is open The motor is connected in star and will produce one third of DOL torque at one
third of DOL current
Star Transition State The motor is connected in star and the resistors are connected across the
delta contactor via the aux [KM4] contactor
24 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Closed Transition State The Main [KM3] contactor is closed and the Delta [KM2] and Star
[KM1] contactors are open Current flows through the motor windings and the transition resistors
via KM4
Delta State The Main and the Delta contactors are closed The transition resistors are shorted out
The Star contactor is open The motor is connected to full line voltage and full power and torque
are available
Effect of Transient in Starter (Open Transient starter)
It is Important the pause between star contactor switch off and Delta contactor switch is on correct
This is because Star contactor must be reliably disconnected before Delta contactor is activated It
is also important that the switch over pause is not too long
For 415v Star Connection voltage is effectively reduced to 58 or 240v The equivalent of 33
that is obtained with Direct Online (DOL) starting
If Star connection has sufficient torque to run up to 75 or 80 of full load speed then the motor
can be connected in Delta mode
When connected to Delta configuration the phase voltage increases by a ratio of V3 or 173 The
phase currents increase by the same ratio The line current increases three times its value in star
connection
During transition period of switchover the motor must be free running with little deceleration
While this is happening ldquoCoastingrdquo it may generate a voltage of its own and on connection to the
supply this voltage can randomly add to or subtract from the applied line voltage This is known as
transient current Only lasting a few milliseconds it causes voltage surges and spikes Known as
a changeover transient
Size of each part of Star-Delta starter
(1) Size of Over Load Relay
For a star-delta starter there is a possibility to place the overload protection in two positions in the
line or in the windings
Overload Relay in Line
In the line is the same as just putting the overload before the motor as with a DOL starter
The rating of Overload (In Line) = FLC of Motor
Disadvantage If the overload is set to FLC then it is not protecting the motor while it is in delta
(setting is x1732 too high)
Overload Relay in Winding
25 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
In the windings means that the overload is placed after the point where the wiring to the contactors
are split into main and delta The overload then always measures the current inside the windings
The setting of Overload Relay (In Winding) =058 X FLC (line current)
Disadvantage We must use separate short circuit and overload protections
(2) Size of Main and Delta Contractor
1 There are two contactors that are close during run often referred to as the main contractor and
the delta contactor These are AC3 rated at 58 of the current rating of the motor
Size of Main Contactor= IFL x 058
(3) Size of Star Contractor
The third contactor is the star contactor and that only carries star current while the motor is
connected in star The current in star is 1 radic3= (58) of the current in delta so this contactor can
be AC3 rated at one third (33) of the motor rating
Size of Star Contactor= IFL x 033
Motor Starting Characteristics of Star-Delta Starter
Available starting current 33 Full Load Current
Peak starting current 13 to 26 Full Load Current
Peak starting torque 33 Full Load Torque
Advantages of Star-Delta starter
The operation of the star-delta method is simple and rugged
It is relatively cheap compared to other reduced voltage methods
Good TorqueCurrent Performance
It draws 2 times starting current of the full load ampere of the motor connected
Disadvantages of Star-Delta starter
Low Starting Torque (Torque = (Square of Voltage) is also reduce)
Break In Supply ndash Possible Transients
Six Terminal Motor Required (Delta Connected)
It requires 2 set of cables from starter to motor
It provides only 33 starting torque and if the load connected to the subject motor requires higher
starting torque at the time of starting than very heavy transients and stresses are produced while
changing from star to delta connections and because of these transients and stresses many
electrical and mechanical break-down occurs
26 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
In this method of starting initially motor is connected in star and then after change over the motor
is connected in delta The delta of motor is formed in starter and not on motor terminals
High transmission and current peaks When starting up pumps and fans for example the load
torque is low at the beginning of the start and increases with the square of the speed When
reaching approx 80-85 of the motor rated speed the load torque is equal to the motor torque and
the acceleration ceases To reach the rated speed a switch over to delta position is necessary and
this will very often result in high transmission and current peaks In some cases the current peak
can reach a value that is even bigger than for a DOL start
Applications with a load torque higher than 50 of the motor rated torque will not be able to start
using the start-delta starter
Low Starting Torque The star-delta (wye-delta) starting method controls whether the lead
connections from the motor are configured in a star or delta electrical connection The initial
connection should be in the star pattern that results in a reduction of the line voltage by a factor of
1radic3 (577) to the motor and the current is reduced to 13 of the current at full voltage but the
starting torque is also reduced 13 to 15 of the DOL starting torque
The transition from star to delta transition usually occurs once nominal speed is reached but is
sometimes performed as low as 50 of nominal speed which make transient Sparks
Features of star-delta starting
1 For low- to high-power three-phase motors
2 Reduced starting current
3 Six connection cables
4 Reduced starting torque
5 Current peak on changeover from star to delta
6 Mechanical load on changeover from star to delta
Application of Star-Delta Starter
The star-delta method is usually only applied to low to medium voltage and light starting
Torque motors
The received starting current is about 30 of the starting current during direct on line start and the
starting torque is reduced to about 25 of the torque available at a DOL start This starting
method only works when the application is light loaded during the start If the motor is too heavily
27 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
loaded there will not be enough torque to accelerate the motor up to speed before switching over
to the delta position
LESSON 1 WIRING SYSTEM OF SINGLE PHASE DISTRIBUTION BOARD
Introduction
28 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
29 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
30 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
31 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 2 WIRING SYSTEM OF SINGLE PHASE LIGHTING CIRCUIT Introduction
Objectives
1 Identify component and the specification
2 Wire component according to the schematic diagram
3 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Wiring bay Perforated metal 180 cm x 180 cm 1
2 Cut out fuse 63 A 240 V 1
3 Neutral link 1
4 Single pole one way switch cw
switch box
5A 240Vac 4
5 single pole two way switch cw
switch box
5A 240Vac 2
6 RCCB In = 40 A Tripping current
100mA240 Vac 50 Hz
1
7 Main switch 32 A 240V 1
8 kWatthour meter 40 A 240 Vac 1
9 Single pole MCB 6A 240 Vac 1
10 Self tapping Wood screw As required
11 DIN rail 35 mm width As required
32 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
12 PVC trunking 50 mm x 50 mm As required
13 Terminal blocks 5 A As required
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
1 One way switch to control one lamp
2 One way switch to control two lamps
3 Two of two way switch to control one lamp
4 Two of single pole two way switch and one of an intermediate switch to control one
lamp
5 One unit of ceiling fan and fan regulator to be controlled by one way switch
4 Test the functionality of completed project
LESSON 3ndash WIRING SYSTEM OF SINGLE PHASE POWER CIRCUIT Introduction
33 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
34 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify types of component and its specification
2 Wire component according to the schematic diagram given
3 Test the functionality of the circuit dead circuit test life circuit test
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board Perforated Metal 1
2 kWh meter 240 V 40 A 1
3 Socket outlet 13A 240Vac 4
4 RCCB 40A Trip Amps
30mA240 Vac
1
5 3 pin socket 240Vac 13A 4
6 Single pole MCB 20A 240 V 2
7 DOL starter 1 kW 240Vac 2
8 1 phase induction motor 2Hp 240 Vac 1
9 Cooker control unit 4kW 240Vac 1
10 Water heater point 4kW 240 Vac 1
11 DIN rail 35 mm As required
12 PVC casing 20mm As required
13 Flexible wires 05 mm As required
14 Terminal block 10 A As required
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Wire two unit of 13 A socket outlet in radial circuit
3 Wire four units of 13 A socket outlet in ring circuit
4 Wire one unit DOL starter for air-conditioner point
5 Wire one unit of cooker control unit point
6 Wire one unit of water heater point
7 Test the functionality of each component by using mmeter or power supply whichever
applicable
8 Wire component according to circuit diagram
9 Test the functionality of completed project dead circuit test life circuit test
Note
35 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Ensure that the correct rating of protection device and size of wire used
LESSON 4ndash CONDUIT BENDING AND TRUNKING FABRICATION TECHNIQUE
Common fitting used in an industrial wiring
Cutting and threading the condute
36 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
37 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
38 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify conduit fitting and the specification
2 Measure and Cut steel conduit according to specified dimension
3 Bend and fabricate conduit at 45 90 according to layout diagram
4 Wire component according to the schematic diagram
5 Test the functionality of the circuit
39 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Conduit Bender Oslash 19 mm ( frac34 ldquo) 1
2 Measuring Tape 3 metre 1
3 Hacksaw frame and blade 30cm 1
4 Conduit cutter 1
5 Pipe Vise 1
6 Pipe Wrench 1
7 Ratchet Dies 20 mm 1
8 Metal trunking 50 mm x 50 mm 1
9 GI conduit 20mm 1
10 End box 20 mm 1
11 Flexible wires 05 mm As required
12 Connectors 5 A As required
13 Single core PVC ins Cable 25 mm 2 As required
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Wire two unit of 13 A socket outlet in radial circuit
3 Wire four unit of 13 A socket outlet in ring circuit
4 Wire one unit DOL starter for air-conditioner point
5 Wire one unit of cooker control unit point
6 Wire one unit of water heater point
7 Test the functionality of each component by using multimeter or power supply whichever
applicable
8 Wire component according to circuit diagram
9 Test the functionality of completed project
Note
Ensure that the rating of protection device and size of wire
K prior to 31 March
2004 (BS 7671)
(formerly)
bare conductor
sleeved at terminations (formerly)
40 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 5 ndashWIRING SYSTEM OF 1 Oslash LIGHTING AND POWER CIRCUIT
POWER CIRCUITSa Radial circuits
Radial circuits are arranged in the same way as item 1 above in lighting layouts in that each socket
outlet is supplied via the previous one
Points to note
1 The number of socket outlets complying with BS 1363 is unlimited for a floor area of up to 50m 2 if
the circuit protection is a 30 A or 32 A cartridge fuse or circuit breaker the cable being 4 mm PVC
copper or 25 mm2 mineral insulated (mi)
2 The number of socket outlets is unlimited for a floor area up to 20 m 2 with any type of circuit
protection of 20 A using 25 mm2 PVC copper cable or 15 mm2 mi
3 The total number of fused spurs is unlimited
b ring final circuits
These circuits are the same as radial circuits except that the final socket outlet is wired back to the
supply position In effect any outlet is supplied from two directions (Fig 152)
Points to note
1 Every twin-socket outlet counts as two single-socket outlets
2 The number of non-fused spurs must not exceed the total number of points on the ring Fig 158
shows seven points on the ring and five spurs
3 The fuse rating of a fused spur box must not exceed 13 A and the current rating of all points supplied
by the fused spur must not exceed 13 A
4 Non-fused spurs must supply no more than one single or one double socket on the ring Fig 158
shows seven points on the ring and five spurs rating of all points supplied by the fused spur must not
exceed 13 A or one stationary appliance
CapacityMain conductor size
copper (mm2)
Earth conductor
size (mm2)
Circuit breaker
capacity (A)
Up to 600 W 15 15 6
600ndash1200 W 1525 15 10
1200ndash1800 W 254 25 16
41 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Ring circuit
(floor area 100 m2)25 15 3032
A2 radial circuit
(floor area 75 m2)40 25 3032
A3 radial circuit
(floor area 50 m2)25 15 20
Air conditioner (15 tonne) 60 60 3032
Cooker 60 60 3032
Water heater 40 40 20
Objectives
1 Identify component and the specification
2 Wire component according to the schematic diagram
3 Test the functionality of the circuit
42 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board Perforated 1
2 Cut out fuse and neutral link 60A 240V 1each
3 kWh meter 240V 40A 1
4 Switched Socket outlet 13A 240Vac 4
5 Single pole two way switch cw switch
box
5A 240Vac 2
6 RCCB ELCB 63 A Tripping current 100mA
415 Vac
1
7 3 pin plug 240Vac 13A 4
8 Single pole MCB 20 A 2
9 Single pole MCB 6A 1
10 Single pole MCB 20A 2
11 DOL starter 240Vac 2
12 1 phase induction motor 2hp 240 Vac 1
13 Self tapping Wood screw As required
14 DIN rail Stainless steel allum35 mm As required
15 PVC pipe 20mm dia As required
16 End box 20 mm dia 4
17 Flexible wires 05 mm 2 As required
18 Connectors 5 A As required
Procedures
43 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
4 Test the functionality of completed project
LESSON 6 ndash WIRING SYSTEM OF 3 Oslash DISTRIBUTION BOARD
Introduction
44 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
45 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
46 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
47 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
48 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify each component and the specification
2 Wire component according to the schematic diagram given
3 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting Board 450 x 600 mm Perforated metal 1
2 5 pin round socket and plug 415V ac 32A 1
3 Cut out fuse 60 A 3
4 Neutral link 1
5 kWatt hour meter 415V 60A 1
6 ELCB RCCB 3P+N In=63A415 Vac I trip= 300mA 1
7 ELCB RCCB 3P+N In=63A415 Vac I trip= 30mA 1
8 Single pole MCB 6A 240 V 3
9 Single pole MCB 20A 240 V 3
10 DOL starter 20 A 240Vac 2
11 Socket outlet 15 A 240 Vac 1
12 Switched Socket outlet 13 A 240 Vac 3
13 Led indicating light 5A 240 Vac 3
14 Single pole 4 gang 1 way switch 5A 240 Vac 2
15 Single pole 2 way switch 5A 240 Vac 2
16 1 phase induction motor 1 kW 240Vac 1
17 Metal trunking 30 mm x30 mm As required
18 Self tapping Wood screw 4 mm x 20 mm As required
19 DIN rail 25 mm x 1mm
20 GI steel rigid conduit 20mm As required
21 Flexible conduit 20mm As required
22 End box 20 mm 4
23 Flexible wires 05 mm 2 As required
24 Single core PVC insulated wire 15 mm 2 As required
25 Single core PVC insulated wires 25 mm 2 As required
26 Terminal block 10 A As required
Procedures
49 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify each components and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
4 Test the functionality of completed project
1 dead circuit test
2 life circuit
Note Proper earthing should be made
50 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 7 ndash WIRING SYSTEM OF THREE PHASE LIGHTING AND POWER CIRCUIT
51 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
52 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify component and the specification
2 Wire component according to the schematic diagram
3 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting bay Board Perforated metal 180 cm x 180 cm 1
2 k Watt hour meter 415V 60A 1
3 MCCB 415V 60A
4 ELCB RCCB In=60A415 Vac I trip=30mA 1
5 5 pin round Socket and
plug
415Vac 32A 4
6 Single pole MCB 6A 1
7 Triple pole MCB 20A 2
8 Triple pole Main switch 60A 1
9 DOL starter 240Vac 2
10 3 phase induction motor 2hp 415 Vac 1
11 1 phase induction motor 1
12 Metal trunking 30 mm x30 mm As required
13 Self tapping Wood screw 4 mm x 20 mm As required
14 DIN rail 25 mm x 1mm
15 GI steel rigid conduit 20mm As required
16 Flexible conduit 20mm As required
17 End box 20 mm 4
18 Flexible wires 05 mm As required
19 Connectors 10 A As required
Procedures
1 Identify each components and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
4 Test the functionality of completed project
1 dead circuit 2 life circuit test
5 Record the current drawn by the load as connected in star and delta
Note Proper earthing should be made
53 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 8 INSPECTION AND TESTING OF ELECTRICAL INSTALLATION
On completion of a wiring installation a number of tests on the installation have to be conducted to
ascertain that the wiring circuits and connected appliances are safe for use Prior to carrying out the
tests an inspection has to be done The results of the inspectionsupervision and test have to be
presented in Form G (as in Appendix IV) and Form H (as in Appendix V)
To have the test certification as in Form H the following tests shall be conducted
i Continuity Test
ii Insulation Resistance Test
iii Polarity Test
iv Earth Electrode Resistance test and
v Residual Current Device Test
1 Continuity Test
There are 3 main types of continuity tests for the final circuits-
i Protection Conductor Continuity Test
ii Final Ring Circuit Conductor Continuity Test
iii Live and Neutral Conductor Continuity Test
a) Protection Conductor Continuity Test
bull To ascertain that all protection conductors are connected in the correct and effective manner
bull Test equipment ndash Multimeter (Ohm range) or Ohm meter
54 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
bull Test Method
1 1048766 Ensure that the main switch RCD and MCB are open circuited (switched off) and all loads
are disconnected
2 1048766 Connected the test leads as in the Figure 81 The meter reading shall be less than 1 Ω
55 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Final Ring Circuit Conductor Continuity Test
bull To ensure that all conductors around the ring circuit have continuity
bull Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
bull Test Method
1 1048766 Disconnect both the supply source live conductors from the MCB the neutral conductor
from the neutral terminals and the earth conductor from the earth terminal in the distribution
fuse box
2 1048766 Connect the test leads as in the Figure 82 (EE)
3 1048766 Repeat the procedure for (L-L) and (N-N)
4 1048766 The meter reading value shall be less than 1 ohm
56 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Live and Neutral Conductor Continuity Test
a To ensure that each conductor in the circuit has continuity
b Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
2 Test Method
1 1048766 Switch off the Main switch RCD and MCB
2 1048766 Disconnect all loads
3 1048766 Switch on all switches in the circuit
4 1048766 Disconnect the fusesfinal circuit breakers and close the circuit
5 1048766 Carry out the test as shown in Figure 83
6 1048766 The meter reading value shall be less than 1Ω
57 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
58 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
CONTINUITY TEST
Insulation Resistance Test
i Ensure that there is no leakage current between phase conductors phase and neutral conductors and
phase conductor and earth
ii Test the strength of the cable insulation
iii Test Equipment ndash Insulation Resistance Tester operating voltage is 250VDC or 500VDC
iv Test Method
1 1048766 Switch off main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
59 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
4 1048766 Carry out test as in the Table below
5 1048766 Meter reading value shall be less than 1 Megaohm
60 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
61 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Insulation resitance test
62 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
INSULATION RESISTANCE TEST BETWEEN CONDUCTORS AND OPPOSITE POLARITY
Polarity Testi Ensure that each fuse or single pole control and protection device is connected only in the phase
conductor
ii Intermediate contact of Edison screw lamp holder is connected to the phase conductor
iii Ensure that phase neutral and earth conductors at socket outlets are connected at the correct
terminals
iv Test Equipment ndash Multimeter (Ohm range) or Ohm meter
v Test Method
1 1048766 Switch off Main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in Figure 85
63 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
5 1048766 Test switches and single phase control devices at the phase conductors
6 1048766 Test socket outlet connection sources
7 1048766 Test Edison screw lamp holder connections
8 1048766 Meter reading value shall be less than 1 Ω
64 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Polarity test
65 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Earth Electrode Resistance Testi To test the earth electrode resistance
ii To ascertain the suitability of the location of the electrode
iii To ensure that the electrode is not buried within the resistance area of another electrode
iv Test equipment ndash Earth Resistance Tester
v Test method -
1 1048766 Terminal rsquoErsquo is connected to the electrode to be tested (green conductor)
2 1048766 Terminal lsquoPrsquo is connected to the potential spike (yellow conductor) at a distance of 10
meters from the earth electrode
3 1048766 Terminal lsquoCrsquo is connected to the current spike (red conductor) at a distance of 20 meters
from the earth electrode
Earth Electrode Resistance Measurement Method (Figure 86)
This test must be repeated at least three times to ensure that the reading is not affected by interacting
earthing regions
i Record the first reading (Z1) Example Z1 = 10 Ω
ii Move the voltage spike to a distance of 6 meters from the original position Record the second
reading (Z2 ) Example Z2 = 10 Ω
iii Move the voltage spike to a distance of 6 meters from the original position Record the third
reading (Z3) Example Z3 = 10 Ω
66 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Residual Current Device Testi Ensure that the residual current device (RCD) trips within the set time on the occurrence of current
leakage to earth
ii Test Equipment ndash RCD Tester RCCB Tester
iii Test Method 1
1 1048766 Use the Trip Test Button
2 1048766 Press the trip button found on the RCD to determine if it trips or otherwise This test would
not be able to determine the sensitivity of the RCD nor the time taken for it to trip
iv Test Method 2
i 1048766 Use a RCD Tester
ii This equipment is equipped with a 13A plug which can be connected to a 13A socket outlet
Select the RCD sensitivity to be the same as the sensitivity of the RCD to be tested to
determine if the RCD can trip The time to trip shall not exceed 40 mS
iii 1048766 Test method ndash
a) Position the selection switch in accordance with the sensitivity of the RCD used
Example 100 mA 01 A
b) Position the operations switch to lsquoNo Triprsquo (frac12 Rated mA = 50) connect the 3 pin plug to
the 13A socket outlet
67 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
c) Switch on the 13A socket outlet ndash ensure that the P-N and P-E lights light up
This shows that the polarity is correct (Note if both the lights as above do not light up the test cannot
be continued)
d) Press the test button ndash the reading shows less than 200 mS and simultaneously the lsquotestrsquo light lights
up and the P-N and P-E lights do not light up At that instant the RCD will not trip
e) Move the selection switch to 180o (+ve wave) ndash repeat steps (d) and (e) Move the operations
switch to lsquoTriprsquo (Rated mA = 100)
g) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200mS
h) Move the selection switch to 0o (-ve wave)
i) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
j) The above test is repeated until a near correct reading is obtained
k) Record the test results
l) Change the operations switch to lsquoFast Triprsquo and press the test button ndash RCD will trip within a
time not exceeding 40 millisecond
m) Repeat a number of times at 0o or 180o
On completion of a wiring installation a number of tests on the installation have to be conducted to
ascertain that the wiring circuits and connected appliances are safe for use Prior to carrying out the
tests an inspection has to be done the following tests shall be conducted
i Continuity Test
ii Insulation Resistance Test
iii Polarity Test
iv Earth Electrode Resistance test and
v Residual Current Device Test
821 Continuity Test
There are 3 main types of continuity tests for the final circuits-
i Protection Conductor Continuity Test
ii Final Ring Circuit Conductor Continuity Test
68 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
iii Live and Neutral Conductor Continuity Test
a) Protection Conductor Continuity Test
bull To ascertain that all protection conductors are connected in the correct and effective manner
bull Test equipment ndash Multimeter (Ohm range) or Ohm meter
bull Test Method
1 1048766 Ensure that the main switch RCD and MCB are open circuited (switched off) and all loads are
disconnected
2 1048766 Connected the test leads as in the Figure 81
3 1048766 The meter reading shall be less than 1 Ω
Final Ring Circuit Conductor Continuity Test
bull To ensure that all conductors around the ring circuit have continuity
bull Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
bull Test Method
1 1048766 Disconnect both the supply source live conductors from the MCB the neutral conductor
from the neutral terminals and the earth conductor from the earth terminal in the distribution
fuse box
2 1048766 Connect the test leads as in the Figure 82 (EE)
3 1048766 Repeat the procedure for (L-L) and (N-N)
4 1048766 The meter reading value shall be less than 1 ohm Figure 82 - Final Ring Circuit Conductor
Continuity Test Ohm Meter
Disconnect both the supply source cables from mcbfuse
Take readings at earth conductors of both sources and note resistance readings
Live and Neutral Conductor Continuity Test
1 To ensure that each conductor in the circuit has continuity
2 Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
3 Test Method
1 1048766 Switch off the Main switch RCD and MCB
2 1048766 Disconnect all loads
3 1048766 Switch on all switches in the circuit
4 1048766 Disconnect the fusesfinal circuit breakers and close the circuit
5 1048766 Carry out the test as shown in Figure 83
6 1048766 The meter reading value shall be less than 1 ohm Figure 83 - Live and Neutral
Conductor Continuity Test Ohm Meter
Insulation Resistance Test
69 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
i Ensure that there is no leakage current between phase conductors phase and neutral conductors and
phase conductor and earth
ii Test the strength of the cable insulation
iii Test Equipment ndash Insulation Resistance Tester Operating voltage is 250VDC or 500VDC
iv Test Method
1 1048766 Switch off main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in the Table below
5 1048766 Meter reading value shall be less than 1 Megaohm
Polarity Test
i Ensure that each fuse or single pole control and protection device is connected only in the phase
conductor
ii Intermediate contact of Edison screw lamp holder is connected to the phase conductor
iii Ensure that phase neutral and earth conductors at socket outlets are connected at the correct
terminals
iv Test Equipment ndash Multimeter (Ohm range) or Ohm meter
v Test Method
1 1048766 Switch off Main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in Figure 85
5 1048766 Test switches and single phase control devices at the phase conductors
6 1048766 Test socket outlet connection sources
7 1048766 Test Edison screw lamp holder connections
8 1048766 Meter reading value shall be less than 1 Ω
Earth Electrode Resistance Test
i To test the earth electrode resistance
70 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
ii To ascertain the suitability of the location of the electrode
iii To ensure that the electrode is not buried within the resistance area of another electrode
iv Test equipment ndash Earth Resistance Tester
v Test method -
1 1048766 Terminal rsquoErsquo is connected to the electrode to be tested (green conductor)
2 1048766 Terminal lsquoPrsquo is connected to the potential spike (yellow conductor) at a distance of 10
meters from the earth electrode
3 1048766 Terminal lsquoCrsquo is connected to the current spike (red conductor) at a distance of 20 meters
from the earth electrode E P C Electrode 10 meter 10 meter
Figure 86 ndash Earth Electrode Resistance Measurement Test Equipment
Earth Electrode Resistance Measurement Method (Figure 86)
This test must be repeated at least three times to ensure that the reading is not affected by interacting
earthing regions
i Record the first reading (Z1) Example Z1 = 10 Ω
ii Move the voltage spike to a distance of 6 meters from the original position Record the second
reading (Z2) Example Z2 = 10 Ω
iii Move the voltage spike to a distance of 6 meters from the original position Record the third
reading (Z3)
Example Z3 = 10 Ω
Residual Current Device Test
71 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
i Ensure that the residual current device (RCD) trips within the set time on the occurrence of current
leakage to earth
ii Test Equipment ndash RCD Tester RCCB Tester
iii Test Method 1
1 1048766 Use the Trip Test Button
2 1048766 Press the trip button found on the RCD to determine if it trips or otherwise This test would
not be able to determine the sensitivity of the RCD nor the time taken for it to trip
iv Test Method 2
1048766 Use a RCD Tester
This equipment is equipped with a 13A plug which can be connected to a 13A socket outlet Select the
RCD sensitivity to be the same as the sensitivity of the RCD to be tested to determine if the RCD can
trip The time to trip shall not exceed 40 mS
1048766 Test method ndash
a) Position the selection switch in accordance with the sensitivity of the RCD used
Example 100 mA 01 A
b) Position the operations switch to lsquoNo Triprsquo (frac12 Rated mA = 50) connect the 3 pin plug to
the 13A socket outlet
c) Switch on the 13A socket outlet ndash ensure that the P-N and P-E lights light up This shows that
the polarity is correct (Note if both the lights as above do not light up the test cannot be
continued)
d) Press the test button ndash the reading shows less than 200 millisecond and simultaneously the
lsquotestrsquo light lights up and the P-N and P-E lights do not light up At that instant the RCD will
not trip
e) Move the selection switch to 180o (+ve wave) ndash repeat steps (d) and (e) = 100)
f) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
g) Move the selection switch to 0o (-ve wave)
h) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
i) The above test is repeated until a near correct reading is obtained
j) Record the test results
k) Change the operations switch to lsquoFast Triprsquo and press the test button ndash RCD will trip within a
time not exceeding 40 mS
l) Repeat a number of times at 0o or 180o
72 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 9 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (DC)
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
73 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Start stop button 240Vac 5A 2
9 Filament lamp (Bulb ) 240Vac 40W 3
10 Overload Relay 415V 20A 3
11 Three phase induction motor 5 hp 3
12 Single phase step down transformer 2500VA 1
13 Single core PVC insulated Cable 1mm 2 As required
14 Single core PVC insulated Cable 25mm 2 As required
15 DIN rail 35 mm As required
16 PVC type Cable tray 50 mm x 50 mm As required
17 Cable ties 4 ldquo As required
18 Flexible wires 05 mm As required
19 PVC Connectors 5 A amp 20 A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the schematic
diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a optional exercise
i Simple DOL starter
ii Forward reverse DOL starter
iii Forward Reverse Dahlander motor
iv Three motors operated in sequence by DOL starter operated by manual push
button or time delay relay
74 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
a One loop per-cycle
b Continuous operation in a loop
c optional circuit design to represent the same task
v Only one out of three motors to be operated at a time (quiz)
4 Test the functionality of completed project
LESSON 10 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (AC)
75 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 1
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Lamp point 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
76 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
11 Overload Relay 415V 20A 3
12 Three phase induction
motor
5 hp 3
13 Single core PVC insulated
Cable
1mm 2 As required
14 Single core PVC insulated
Cable
25mm 2 As required
15 DIN rail 35 mm As required
16 PVC type Cable tray 50 mm x 50 mm As required
17 Cable ties 4 ldquo As required
18 Flexible wires 05 mm As required
19 PVC Connectors 5 A amp 20 A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the
schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram optional exercise
4 Simple DOL starter
5 Forward reverse DOL starter
6 Test the functionality of completed project
77 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 1
78 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
cm
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Indicating light 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
11 Overload Relay 415V 20A 3
12 Three phase induction motor 5 hp 3
13 Single phase step down
transformer
2500VA 1
14 Single core PVC insulated
Cable
1mm 2 As required
15 Single core PVC insulated
Cable
25mm 2 As required
16 DIN rail 35 mm As required
17 PVC type Cable tray 50 mm x 50 mm As required
18 Cable ties 4 ldquo As required
19 Flexible wires 05 mm As required
20 PVC Connectors 5 A amp 20 A 240 V As required
21 Single pole MCB 6A 240 V 1
22 Single pole MCB 2A 240 V 1
23 Triple pole MCB 20A 415 V 1
24 Mounting board 30 cm x 40 cm x 3
cm
1
25 Relay cw 11 pin socket 10 A 240 Vac 2
26 Time delay relay 10 A 240 Vac 3
27 Triple pole Contactor 20A 240Vac 3
28 Batten type Lamp holder 240Vac 10 A 3
29 Start stop button 240Vac 10A 2
30 Indicating light (Bulb ) 240Vac 25W 3
31 Overload Relay 415V 20A 1
32 Three phase dahlander type
induction motor
5 hp 1
33 Single phase step down
transformer
24024Vac
2500VA
1
79 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
34 Single core PVC insulated
Cable
1mm 2 As required
35 Single core PVC insulated
Cable
25mm 2 As required
36 DIN rail 35 mm As required
37 PVC type Cable tray 50 mm x 50 mm As required
38 Cable ties 4 ldquo As required
39 Flexible wires 075 mm As required
40 PVC Connectors 5 A amp 20 A 240 V As required
41 Terminal block 20A 240Vac As required
Procedures
5 Identify each component according to specification and quantity required from the schematic
diagram attached
6 Test the functionality of each component by using multi-meter or power supply whichever
applicable
7 Wire component according to circuit diagram
8 Three motors operated in sequence by DOL starter operated by manual push button or time
delay relay
a One loop per-cycle
b Continuous operation in a loop
c optional circuit design to represent the same task
d Only one out of three motors to be operated at a time (quiz)
9 Test the functionality of completed project
80 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
BASIC DESIGN INDUSTRIAL MOTOR CONTROL (SEQUENCE CONTROL)
THREE PHASE INDUCTION MOTOR OPERATED IN SEQUENCE BY DIRECT ON LINE
STARTER
LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
81 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
82 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Lcd lamp indicator 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
11 Overload Relay 415V 20A 3
12 Three phase induction motor 5 hp 3
13 Single phase step down transformer 2500VA 1
14 Single core PVC insulated Cable 1mm 2 As required
15 Single core PVC insulated Cable 25mm 2 As required
16 DIN rail 35 mm As required
17 PVC type Cable tray 50 mm x 50 mm As required
18 Cable ties 4 ldquo As required
19 Flexible wires 1 mm Oslash As required
20 PVC Terminal block 10A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the schematic
diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a optional exercise
i Forward Reverse dahlander motor
4 Test the functionality of completed project
83 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
THREE PHASE DAHLANDER TYPE INDUCTION MOTOR OPERATED FORWARD AND
REVERSE OPERATION BY DIRECT ON LINE STARTER
84 ndash 99EASYTECH ENTERPRISE
LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
Introduction
If a motors windings are connected in the star configuration any two phases will be in series across
the supply and hence the line current will be smaller(by 577) than if the windings were connected in
the delta arrangement
Hence larger-type motors with heavy starting currents are first connected in star and then when the
starting currents fall in delta This of course means that all six of the ends of the windings must be
brought to terminations outside the casing (Fig 833)
EZTECH
EZTECH ELECTRICAL INSTALLATION GUIDE
The automatic version of this starter incorporates a timing relay which automatically changes the
connections from star to delta Figs 834 and 835 show the wiring and schematic diagrams for a star
delta starter
Objectives
1 Identify component and the specification
2 Design forward reverse star delta starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
2 ndash 99EASYTECH ENTERPRISE
REV -C
LEGENDMCCB Moulded Case Circuit BreakerTOR Thermal Over Load RelayFOW-C Mains Forward ContactorREV-C Mains Reverse ContactorDC Delta ContactorSC Star ContactorS-SW Mains Selector Switch
SC
V2
W2
U2
DC
V1
W1
U1
TOR
TOR
FOW-C
30A MCCB
TOR
MAIN CIRCUIT FORWARD REVERSE STAR DELTA
RYBN S
-SW
3 PHASEINDUCTION MOTOR
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Relay 10 A 240V 3
5 Triple pole Contactor
6 cw NO NC auxiliary contact
240Vac 20 A 4
7 Overload Relay 415 V 1
8 LED indicator 240vac 5 A 4
9 Start stop button 240Vac 5A 2
10 DIN rail 35 mm As required
11 Flexible wires 1 mm As required
12 Single core PVC insulated
wire
25 mm As required
13 Terminal block 20 A As required
14 Squirrel cage motor 5kW 1
15 5 pin plug and socket 415V 20A 1
16 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
3 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
a Manual star delta
b Manual Forward reverse star delta starter
c Automatic star delta starter
d Automatic Forward reverse star delta starter
4 Test the functionality of completed project
4 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
Objectives
1 Identify component and the specification
2 Design auto transformer starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
5 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Autotransformer starter is used to start a 3 phase induction motor that has a rating between 10 to 15 hp
6 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Autotransformer set 10Kw 415 V 50 Hz 1
5 Triple pole Contactor 240Vac 4
6 Batten type Lamp holder 240 Vac 105 A 4
7 Start stop button 240Vac 10A 4
8 Filament lamp (Bulb ) 240Vac 40W 4
9 DIN rail 35 mm As required
10 Flexible wires 1 mm As required
7 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
11 Single core PVC insulated
wire
25 mm As required
12 Terminal block 20 A As required
13 Squirrel cage motor 10kW 1
14 5 pin plug and socket 415V 20A 1
15 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a open transient autotransformer starter
b close transient autotransformer starter
c Forward reverse autotransformer starter
4 Test the functionality of completed project
8 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
Objectives
1 Identify component and the specification
2 Design rotor resistance starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
9 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Rotor Resistor set 10kW 1
5 Triple pole Contactor 240Vac 20A 4
6 Indicating light 240vac 5 A 4
7 Start stop push button 240Vac 5A 4
8 DIN rail 35 mm As required
9 Flexible wires 1 mm 2 As required
10 Single core PVC insulated wire 25 mm 2 As required
11 Terminal block 20 A As required
12 Slip Ring motor 10kW 1
13 5 pin round 3 phase socket 415V 20A 1
14 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
10 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
4 Test the functionality of completed project
a Dead circuit test b Life circuit test
5 Measure starting and running Amps
LESSON 16
TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
An installation in general will suffer damage
Damage usually occurs on the electric motor control as follows
1 Damage to the main circuit
2 Damage to the control circuit
The cause of the damage
i Overcurrent overload short circuit
ii Leakage current to ground
iii Equipment malfunction
iv The main control circuit
a Trip of main circuit protection devices fire
b Defect of motor terminal such as short circuit fire loose
v The control circuit is not functioning -
a contactor relay relay time overload relay does not work damaged burned
b Loose cable connection disconnected
Detecting and Repairing Damage
Examples of damage are as follows
i Motor does not work
ii Motor function and overload relay trips
iii Motor function but only partially functional control circuit
Methods of detecting damage
Among the known methods necessary to detect damage are as follows
1 Turn off the electricity at the main switch (main switch) in order to avoid any danger during the
work carried out to detect damage
2 Check all the protective gear that controls the motor control main circuit
11 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
3 Make sure the damage function control circuit
4 Check the control circuit according to the schematic circuit diagram of the motor control
5 Check the operation of the control circuit
Note
Use wiring that has been installed on the SYSTEM OF MOTOR CONTROL BOARD by Forward
Reverse control circuit for Star Delta to test and look for damage
SELF-ASSESSMENT QUESTIONS
1 (a) Explain what is meant by the term lsquoback emfrsquo in a motor
(b) Outline the basic differences between series shunt and compound wound dc motors
2 (a) With the aid of diagrams explain how the speed of series shunt and compound-wound motors
may be controlled
(b) A 440V dc shunt-wound motor has a field resistance of 200R and an armature resistance of 06 R
When its speed is 20 rev d second the current drawn from the supply is 122A Calculate its back
emf at this speed If the speed were decreased to 19 revssecond the field flux remaining unchanged
calculate the new back emf and the new armature current
3 A load of 64 kW at 240 V is supplied from the terminals of a shunt-wound dc generator The field
resistance is 180 A Calculate the armature current
4 (a) Explain with the aid of a diagram how a rotating magnetic field may be
(b) What is meant by lsquosynchronous speedrsquo
Calculate the synchronous obtained speed of a 12 pole motor if the supply frequency is 50Hz
5 (a) Explain the action of a synchronous motor
(b) What methods are available to start a synchronous motor Explain with diagrams
6 (a) Explain the action of a cage induction motor
(b) What is meant by the term lsquosliprsquo
Calculate the percentage slip of a six pole induction motor running at 162 revssecond from a 50 Hz
supply
7 Describe with sketches three different ways of starting a single-phase induction motor
12 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
8 Explain with the aid of a sketch the action of a three-phase DOL starter
What are dashpots used for How are remote start and stop buttons connected
9 A I0 kW 240V 50Hz single-phase cage rotor induction motor is 85efficient and has a PF of 068
lagging Calculate the motor current and the value of capacitor required to raise the PF to 093
lagging
10 Calculate the torque developed by an 18 kW four-pole induction motor run at 35 slip from a
50Hz supply
APPENDIX 1
13 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 11
14 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 111
Attachment Reference
httpswwwtlc-directcoukBook621htm
httpwwwstgovmyindexphpms
15 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
ELECTRICITY SUPPLY SPECIFICATIONS
Electricity supply for domestic consumers according to MS IEC 60038 standards meets the
following specifications -
i Single phase supply with nominal voltage of 230V range +10 -6
ii Three phase supply with nominal voltage of 400V range +10 -6
iii Permitted frequency is 50Hz + 1
iv Earthing system type (TT System) as in Figure 21 and Figure 22
4 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Legal Requirements
Regulation 11(1) of the Electricity Regulations 1994 states that all wiring or rewiring of an
installation or extension to an existing installation which shall be carried out by an Electrical
Contractor or a Private Wiring Unit have to obtain the approval in writing from a licensee or supply
authority
1 Planning of Electrical Wiring Work
Prior to carrying out wiring work the wiremancontractor should plan and determine the tasks to be
undertaken so that the work carried out is tidy neat and safe to be used The wiremancontractor shall
-i Undertake a site visit
5 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
ii Determine the consumer load requirements
iii Calculate the maximum load demand and
iv Submit the plans drawings and specifications
The planning flow chart for building wiring installations is as shown in Figure 31
11 Site Visit
The purpose of the site visit is to determine -
i Electrical equipment suitable for use
ii Maximum load demand
iii Single or three phase incoming supply
iv Type of wiring and Equipment arrangement
Determining Consumer Load RequirementsWith the aid of the building floor plans the installation requirements such as the proposed load
placement of electrical equipment and installation design plans can be determined
11 Calculating Maximum Load Demand
The estimate of the maximum load demand is for determining the specifications of the wiring
equipment such as the cables and plans
According to clause 311 of MS IEC 60364 Part 1 to determine the maximum demand for each circuit
while ensuring an economic and reliable design within the permitted voltage drop limits Diversity
factors may be taken into account The maximum current demand calculations for each circuit must be
prepared These details will show the current requirements in amperes for each phase and also assist
in determining the cable sizes
Refer to the Third Schedule (Table A and Table B) and Regulation 11(2) of the Electricity Regulations
1994 to estimate the maximum current demand and the diversity factors that may be used for domestic
installations
12 Submission of the Plans Drawings and Specifications Regulation 65 of the Electricity
Regulations 1994 states that the eligibility to submit plans is as follows -
i Wireman with Single Phase Restriction ndash Low voltage single phase up to 60 A
ii Wireman with Three Phase Restriction ndash Low voltage up to 60A
6 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
2 CONTROL AND PROTECTION SYSTEM FOR ELECTRICAL WIRING
7 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
8 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
21 Selection of Control and Protection System for Electrical Wiring
Control and protection of a wiring is a system of separationisolation and switching together with the
protection system which are needed in every domestic wiring installation
22 Isolation and Switching
Examples of isolation and switching are switches power plugs socket outlets and circuit breakers
Their function is to manually connect and break the supply in a particular circuit without interfering
with other circuits
They also aim to prevent the danger of electrical shocks during maintenance testing fault finding and
repair works
23 Protection
This provides protection from dangers caused by electrical currents such as over current earth
leakage current short circuit lightning etc to the wiring system electrical equipment or consumer
The circuit below shows the isolation and protection devices which must be installed in a domestic
electrical wiring system
1 Current Protection
In general protection from the dangers of current can be divided into two aspects namely
i Overcurrent Protection (Over Load or Short Circuit) Properly rated circuit breakers or fuses suitable
for over load or short circuit protection must be used
9 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
The circuit breakers or fuses must be installed on the live conductors only For three phase circuits all
the circuit breakers or fuses must be combined in one set of circuits
Selection of over current devices must be based on the short circuit fault current levels of the circuit
breaker or main switch (kA)
ii Earth Leakage Current Protection
Properly rated Residual Current Devices (RCD) must be used for protection from earth leakage
currents (to prevent electric shocks)
a) Regulation 36(1) of the Electricity Regulations 1994 states that for a place of public entertainment
protection against earth leakage current must be provided by a residual current device of sensitivity
not exceeding 10 mA
b) Regulation 36(2) of the Electricity Regulations 1994 states that for a place where the floor is likely
to be wet or where the wall or enclosure is of low electrical resistance protection against earth leakage
current must be provided by a residual current device of sensitivity not exceeding 10 mA
c) Regulation 36(3) of the Electricity Regulations 1994 states that for an installation where hand-held
equipment apparatus or appliance is likely to be used protection against earth leakage current must be
provided by a residual current device of sensitivity not exceeding 30 mA and
d) Regulation 36(4) of the Electricity Regulations 1994 states that for an installation other than the
installation in (a) (b) and (c) protection against earth leakage current must be provided by a residual
current device of sensitivity not exceeding 100 mA
CABLE SELECTION
31 Selection of Wiring Cable Type
The selection of the cable size has to take into consideration the following-
i All wiring cables must be PVC or PVCPVC insulated with copper conductors Conductors with
cross sectional areas of 16mm2 or less must be of copper Aluminium conductors are not permitted
Refer to Table 4D1A in Appendix II for the current carrying capacities of copper conductor
ii Cables for swimming pools must be water resistant PE (polyethylene) insulated
10 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
iii The selected cable must be capable of delivering the electrical energy efficiently
iv The cable size allows it to carry the current without heating the cable
v The voltage drop must not exceed 4 of the supply voltage Refer to Table 4D1B in Appendix III
vi The cable insulation must be suitable for the surrounding conditions of the installation such as the
ability to withstand the surrounding temperatures and the ability to provide mechanical protection
vii Each conductor in the installation must be protected from overcurrent by means of overcurrent
protection devices needed to prevent damage to the cable insulation
32 Factors Related to Cable Current Carrying CapacityThe following factors in relation to the current carrying capacity of cables must be taken into
consideration-
i Surface wiring using clips ndash group factor
ii Wiring using conduits ndash space factor 40
iii Wiring using ducts ndash space factor 45
iv Concealed wiring ndash group factor and
v Concealed wiring using ducts ndash surrounding temperature factor
Use of Minimum Cross Sectional Area Rating of Wiring ConductorsThe following are the minimum cross sectional areas of conductors based on their applications-
Use of Protection Conductor Minimum Cross Sectional Area Rating
In Comparison with Phase Conductor Cross Sectional Area
The following table shows the protection conductor minimum cross sectional area in comparison
with the phase conductor cross sectional area
Functions and Colour Identification of Non Flexible Cables
The following table shows the functions and colour identification of non flexible cables
11 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
33 Use of Minimum Cross Sectional Area Rating of Wiring Conductors
The following are the minimum cross sectional areas of conductors based on their applications-
34 Use of Protection Conductor Minimum Cross Sectional Area Rating
In Comparison with Phase Conductor Cross Sectional Area
The following table shows the protection conductor minimum cross sectional area in comparison
with the phase conductor cross sectional area
Use of Minimum Cross Sectional Area Rating of Wiring Conductors
The following are the minimum cross sectional areas of conductors based on their applications-
Use of Protection Conductor Minimum Cross Sectional Area Rating
In Comparison with Phase Conductor Cross Sectional Area
The following table shows the protection conductor minimum cross sectional area in comparison
with the phase conductor cross sectional area
Functions and Colour Identification of Non Flexible CablesThe following table shows the functions and colour identification of non flexible cables
12 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Flexible Cables
i Flexible cables of cross sectional area less than 40 mm2 are used in installations for electrical
accessories such as ceiling roses lamp fixtures or attachments socket plugs for mobile
appliances etc
ii Flexible cables shall not be used for permanent wiring
iii Flexible cables for the permanent use of electrical appliances should not exceed 3 meters in
length
37 Functions and Colour Identification of Flexible Cables
Conductor Insulation and Types of WiringVarious material and insulation layers are used for conductor protection Cable selection in
accordance to insulation layers must be done correctly for the type of the wiring installation as
shown in the table below
Functions and Colour Identification of Non Flexible CablesThe following table shows the functions and colour identification of non flexible cables
3 SELECTION OF WIRING ACCESSORIES
i All wiring accessories to be used have to be of those approved by the Energy Commission and
labeled with labels issued by SIRIM For all wiring using UPVC conduits -
13 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
a) Switches socket outlets 3 pin plugs ceiling roses connectors sockets ndash construction material shall
be of polycarbonate type
iii For all wiring using metal conduits - Switches socket outlets and connectors ndash construction
material shall be of metal clad type and All accessories shall be effectively earthed
iv Switch fuse used in single phase installations shall have the fuse permanently connected and not
move with the fuse
v Fuse switch used in 3 phase domestic installations also has fuse and switch The fuse connector is
installed together to allow the fuse to move simultaneously with the switch
vi Lamp
a) Fluorescent lamps using magnetic ballasts (watt loss not exceeding 6 watts) shall be
equipped with dry paper type capacitor
b) Fluorescent lamps using electronic ballasts or high frequency electronic ballasts do not
need capacitors
c) Outdoor domestic lamp installations shall use weather proof and water proof lamps
d) Submerged light installations (example in swimming pools fountains etc) shall have water
proof lamps with a voltage not exceeding 12 Volt AC
vii Electric water heaters is divided into 2 types namely
1 instantaneous water heaters and
2 stored water heaters (storage tank type)
a) Instantaneous water heaters shall be equipped with a 2 pole control switch and its own
residual current device
b) Storage water heaters (storage tank type) shall be installed with an
Water heaters exceeding 3kW shall be permanently connected to a 20A30A rated circuit
breakerfuse with an isolator switch and residual current device
viii Electric cookers exceeding 3kW shall have its own circuit connected permanently to a 30A rated
circuit breaker or fuse with an isolator switch and cooker control unit incorporated with a 13A socket
outlet Two or more cooker appliances may be installed in the same room within a distance of 2
meters
ix Electric motors (fence gate air conditioners fountains swimming pools fish ponds water
pumps) exceeding 373W but not exceeding 2238W shall be connected permanently to a 20A30A
rated circuit breakerfuse together with an isolator motor starter and 15A socket outlet
14 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
The motor starter shall be of Direct-On-Line type with the appliance together with the contactor
overload relay and on-off control The circuit breakerfuse which controls the motor circuit shall be
capable of withstanding the starting current of the motor
x Electric bells ndash the circuit shall have a push button switch and a ACDC transformer
xi Ceiling fans shall conform to clause 21101 of the MS 12192002 standard with regards to test on
the suspension system of ceiling fans
EARTHING OF ELECTRICAL INSTALLATIONS51 Earthing
Earthing is a connection system between the metallic parts of an electrical wiring system and the
general mass of the earth This will provide an easy path with a low impedence or resistance to earth to
enable the protection system to operate effectively It will thus ensure safety to human
beingsconsumers from the dangers of electric shocks if earth leakage currents are present In general
an electrical installation is earthed because of -
i Safety reasons
ii Protection system requirements
iii Need to limit over voltages
iv Need to provide a path for electrical discharge
v Legal requirements
52 Classification of Earthing
Generally earthing can be divided into 2 parts namely -
i System Earthing
a To isolate the system under fault conditions
b To limit the potential difference between conductors which are not insulated in an area
c To limit the occurrence of over voltages under various conditions
ii Equipment Earthing
Equipment earthing is undertaken to protect human beingsconsumers If a live source comes into
contact with the equipment body electrical energy will flow to the earth without flowing through the
human being consumerrsquos body This is because of the fact that the human body has a greater
resistance compared with the resistance to earth
53 Types and Functions of Earthing Accessories
Earthing accessories are as follows -
i Earthing Electrode
Copper jacketed steel core rods are used as electrodes for domestic wiring
ii Equipotential Bonding
15 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
This is the conductor which is connected between the consumer earthing point and the exposed
metallic part The minimum cable size for this purpose is 10 mm2
iii Protection Conductor
This is the conductor which connects the consumer earthing point with other parts of the installation
which needs earthing Its size is as follows-
a) Same size as the phase cable up to a size of 16mm2
b) 16 mm2 if the phase cable size is between 16 mm2 and 35 mm2
c) Half the size of the phase cable if the size of the phase cable exceeds 35 mm2
54 Earthing Arrangements Using a TT System
i The first alphabet indicates the earthing arrangements from the supply side
ii The second alphabet indicates the earthing arrangement in the consumerrsquos installation
T ndash first Indicates that the supply system has its own earthing arrangements
T ndash second Indicates that all metallic frames of the electrical appliances etc are connected directly to
earth
Parts that are Required to be Earthed
i All metallic structures in the wiring system (non current carrying) such as metallic covers conduits
ducts the armour of catenary wires etc
ii A secondary winding point in a transformer and
iii Frame of metal roof truss
56 Parts that are not Required to be Earthed
i Short isolated metallic parts for mechanical protection of cables which have non metallic sheaths
other than conduits which are connected at entry points between the building and conduits which
protect discharge lamp cables
ii Cable clips for installing cables
iii Metallic covers for lamps
16 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
iv Small metallic parts such as screws and name plates which are isolated by means of insulation
v Metallic lamp parts for filament lamps in water proof floors
57 Termination to Earth
The termination to earth is done as shown in Figure 72
Earth Electrode Resistance
The maximum permitted earth electrode resistance for different types of installations is as shown in
the Table below
Earth electrode for installations protected by RCDs of sensitivity 100mA 10 Ω
Lightning arrestor earth electrode 10 Ω
Legal Requirements
i Sub regulation 12(1) and 12(2) of the Electricity Regulations 1994 state that any electrical wiring in
an installation shall be under the immediate supervision of a Wireman with Single Phase Restriction or
Three Phase Restriction Upon completion the Wireman shall certify a Supervision and Completion
Certificate
ii Sub regulation 13(1) and 13 (2) of the Electricity Regulations 1994 state that the installation shall
be tested by a Wireman with Single Phase Restriction or a Wireman with Three Phase Restriction
authorized to test any installation and who shall certify a Test Certificate for the installation
iii Sub regulation 14(1) of the Electricity Regulations 1994 states that the Supervision and
Completion Certificate and the Test Certificate as in regulations 12 and 13 shall be in Forms G and H
respectively as prescribed in the First Schedule
17 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
4 SAFETY REQUIREMENTS FOR ELECTRICAL WIRING WORKS IN RESIDENTIAL BUILDINGS
61 Safety Requirements
Safety requirements for electrical wiring works have to be followed to eliminate any accidents which
can result in physical damage or loss of life or property Failure to meet the safety regulations may
result in workers consumers or the public being inflicted with electrical shocks
In addition to this safety steps will also encourage workers or electricity consumers who are
disciplined and who always give importance to safety
62 Safety Steps
Safety requirements have to be followed whenever electrical works are undertaken in a residential
building
i Personal Safety
a Use suitable personal protection equipment as needed such as safety shoes gloves safety helmet
etc when at the work place
b Use safety clothing suitable for the work to be undertaken
c Do not wear jewellery or decorative items such as rings watches chains etc while carrying out
electrical works
ii Safety at the Work Place
a Acquire knowledge about the dangers of electrical works that is to be undertaken and how to deal
with those dangers
b Always adhere to the safety regulations which have been set for the work place
c Ensure that the electricity supply is switched off before carrying out the works
d Acquire the needed knowledge and practice a cautious and calm attitude while working ensure
cleanliness in and around fellow workers
e While working at elevated places the worker should always use suitable equipment such as wooden
or aluminium ladders iron scaffoldings or platforms safety belts or other equipment needed to ensure
that the work can be undertaken safely
f Use electrical equipment which is operational and safe to be used and ensure that the supply for it is
being supplied through a residual current device (RCD) with a sensitivity of 30 mA
g Ensure that exposed temporary supply electrical cables have mechanical protection
h If inflammable or corrosive material is present necessary safety steps have to be undertaken as
required by the relevant safety regulations
63 Dangers of Electrical Shocks
i Electrical Shock
Electrical shocks can occur due to direct or indirect contact
a Direct Contact
18 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Direct contact occurs when the worker or consumer receives an electrical shock on touching directly a
live conductor or cable
b Indirect Contact
Here the electric shock occurs due to contact with a part which is connected to the electrical
installation and not to a direct contact with a live cable or conductor possibly due to damages in the
appliance or insulation resulting in leakages of current
Why Electric Shocks Occura Unsafe Work Method or Action Undertaking Electrical Work Without Disconnecting the
Supply
Maintenance or circuit testing work done without disconnecting the supply will have a high possibility
of electrical shocks occurring
bull Not Following Safe Work Procedures
To eliminate the occurrence of electrical shocks each worker has to always follow safe work
procedures which are set by regulations and standards
b Defects in the Electrical System
i Leakage Current
Leakage currents or earth leakage currents can result in the metallic frames becoming live and
energised This can give rise to the danger of electrical shock to the worker consumer or the public if
they hold or come into contact with the metallic frame
ii Exposed Conductor or Disconnected Cable
Exposed conductors or cables which are broken and are alive (energised) can result in electrical shock
when touched The supply source must be immediately isolated or switched off and a report must be
made to the responsible entity
64 First Aid and Basic Pulmonary Resuscitation
i First Aid
First aid is the initial assistance given to a person who has met with an accident is sick or is injured to
prevent the condition of the victim from becoming more serious while awaiting the arrival of the
paramedics (ambulance) or before being brought to the hospital
i Pulmonary Resuscitation
Pulmonary resuscitation has to be undertaken to assist the victim who has breathing difficulties as a
result of being drowned receiving an electrical shock etc Pulmonary resuscitation has to be carried
out in accordance to the correct method as stated in the first aid manuals issued by accredited first aid
bodies
ii First Aid Box
19 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
A first aid box has to be provided by the building owner construction site supervisor or brought
personally by the worker under the supervision of the responsible person
65 Training Programme
The management shall conduct periodic training programmes for the workers with regards to work
safety on aspects including the following -
i Dangers of electrical work being undertaken and how to control those dangers
ii The safety regulations set for the work place and
iii First aid procedures
66 Fire Prevention
Fire Extinguisher A suitable functioning fire extinguisher to control fires has to be made available at
the work place at all times
67 Competent Person
The Electricity Regulations 1994 require that all electrical work has to be undertaken by or under the
direct supervision of a competent person registered with the Energy Commission Besides that the
electrical contractor undertaking the electrical work has also to be registered with the Energy
Commission The installation owner thus has to ensure that the appointed electrical contractor is
registered with the Energy Commission and that the registration is still valid
INSTALLATION CIRCUITS AND SYSTEMS1 Block diagrams
These show using squares rectangles etc the sequence of a system without too much technical detail
eg Figures 1517 and 1526
2 Layout diagrams
These are very similar to block diagrams but they indicate more technical detail and tend to show
items in their correct geographical location (eg Figures 1518 and 1519)
3 Circuitschematic
These show how a circuit functions and takes no account of exact locations of terminals or equipment
(eg Figures 1528 1529 1532 1534 etc)
4 Wiring diagram
These indicate how a circuit or system is physically wired (eg Figures 152 154 156 etc)
Most induction motors are started directly on line but when very large motors are started that way
they cause a disturbance of voltage on the supply lines due to large starting current surges To limit the
starting current surge large induction motors are started at reduced voltage and then have full supply
voltage reconnected when they run up to near rotated speed Two methods are used for reduction of
starting voltage are star delta starting and auto transformer stating
20 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Working Principal of Star-Delta Starter
This is the reduced voltage starting method Voltage reduction during star-delta starting is achieved by
physically reconfiguring the motor windings as illustrated in the figure below During starting the
motor windings are connected in star configuration and this reduces the voltage across each winding 3
This also reduces the torque by a factor of three After a period of time the winding are reconfigured as
delta and the motor runs normally
StarDelta starters are probably the most common reduced voltage starters They are used in
an attempt to reduce the start current applied to the motor during start as a means of reducing the
disturbances and interference on the electrical supply
Traditionally in many supply regions there has been a requirement to fit a reduced voltage
starter on all motors greater than 5HP (4KW) The StarDelta (or WyeDelta) starter is one of the
lowest cost electromechanical reduced voltage starters that can be applied
The StarDelta starter is manufactured from three contactors a timer and a thermal overload
The contactors are smaller than the single contactor used in a Direct on Line starter as they are
controlling winding currents only The currents through the winding are 1root 3 (58) of the
current in the line
There are two contactors that are close during run often referred to as the main contractor and
the delta contactor These are AC3 rated at 58 of the current rating of the motor The third
contactor is the star contactor and that only carries star current while the motor is connected in star
The current in star is one third of the current in delta so this contactor can be AC3 rated at one
third (33) of the motor rating
Star-delta Starter Consists following units
1) Contactors (Main star and delta contactors) 3 Norsquos (For Open State Starter) or 4 Norsquos (Close
Transient Starter)
2) Time relay (pull-in delayed) 1 No
3) Three-pole thermal over current release 1No
4) Fuse elements or automatic cut-outs for the main circuit 3 Nos
5) Fuse element or automatic cut-out for the control circuit 1No
Power Circuit of Star Delta Starter
1 The main circuit breaker serves as the main power supply switch that supplies electricity to the
power circuit
2 The main contactor connects the reference source voltage R Y B to the primary terminal of the
motor U1 V1 W1
21 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
3 In operation the Main Contactor (KM3) and the Star Contactor (KM1) are closed initially and
then after a period of time the star contactor is opened and then the delta contactor (KM2) is
closed The control of the contactors is by the timer (K1T) built into the starter The Star and Delta
are electrically interlocked and preferably mechanically interlocked as well In effect there are
four states
4 The star contactor serves to initially short the secondary terminal of the motor U2 V2 W2 for the
start sequence during the initial run of the motor from standstill This provides one third of DOL
current to the motor thus reducing the high inrush current inherent with large capacity motors at
startup
5 Controlling the interchanging star connection and delta connection of an AC induction motor is
achieved by means of a star delta or wye delta control circuit The control circuit consists of push
button switches auxiliary contacts and a timer
Control Circuit of Star-Delta Starter (Open Transition)
1 The ON push button starts the circuit by initially energizing Star Contactor Coil (KM1) of star
circuit and Timer Coil (KT) circuit
2 When Star Contactor Coil (KM1) energized Star Main and Auxiliary contactor change its
position from NO to NC
3 When Star Auxiliary Contactor (1)( which is placed on Main Contactor coil circuit )became
NO to NC itrsquos complete The Circuit of Main contactor Coil (KM3) so Main Contactor Coil
energized and Main Contactorrsquos Main and Auxiliary Contactor Change its Position from NO
To NC This sequence happens in a friction of time
4 After pushing the ON push button switch the auxiliary contact of the main contactor coil (2)
which is connected in parallel across the ON push button will become NO to NC thereby
providing a latch to hold the main contactor coil activated which eventually maintains the
control circuit active even after releasing the ON push button switch
5 When Star Main Contactor (KM1) close its connect Motor connects on STAR and itrsquos
connected in STAR until Time Delay Auxiliary contact KT (3) become NC to NO
6 Once the time delay is reached its specified Time the timerrsquos auxiliary contacts (KT)(3) in
Star Coil circuit will change its position from NC to NO and at the Same Time Auxiliary
contactor (KT) in Delta Coil Circuit(4) change its Position from NO To NC so Delta coil
energized and Delta Main Contactor becomes NO To NC Now Motor terminal connection
change from star to delta connection
7 A normally close auxiliary contact from both star and delta contactors (5amp6)are also placed
opposite of both star and delta contactor coils these interlock contacts serves as safety
switches to prevent simultaneous activation of both star and delta contactor coils so that one
22 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
cannot be activated without the other deactivated first Thus the delta contactor coil cannot be
active when the star contactor coil is active and similarly the star contactor coil cannot also
be active while the delta contactor coil is active
8 The control circuit above also provides two interrupting contacts to shutdown the motor
The OFF push button switch break the control circuit and the motor when necessary The
thermal overload contact is a protective device which automatically opens the STOP Control
circuit in case when motor overload current is detected by the thermal overload relay this is to
prevent burning of the motor in case of excessive load beyond the rated capacity of the motor
is detected by the thermal overload relay
9 At some point during starting it is necessary to change from a star connected winding to a
delta connected winding Power and control circuits can be arranged to this in one of two
ways ndash open transition or closed transition
What is Open or Closed Transition Starting
(1) Open Transition Starters
Discuss mention above is called open transition switching because there is an open state between
the star state and the delta state
In open transition the power is disconnected from the motor while the winding are reconfigured via
external switching
When a motor is driven by the supply either at full speed or at part speed there is a rotating
magnetic field in the stator This field is rotating at line frequency The flux from the stator field
induces a current in the rotor and this in turn results in a rotor magnetic field
When the motor is disconnected from the supply (open transition) there is a spinning rotor within
the stator and the rotor has a magnetic field Due to the low impedance of the rotor circuit the time
constant is quite long and the action of the spinning rotor field within the stator is that of a
generator which generates voltage at a frequency determined by the speed of the rotor When the
motor is reconnected to the supply it is reclosing onto an unsynchronized generator and this result
in a very high current and torque transient The magnitude of the transient is dependent on the
phase relationship between the generated voltage and the line voltage at the point of closure can
be much higher than DOL current and torque and can result in electrical and mechanical damage
Open transition starting is the easiest to implement in terms or cost and circuitry and if the timing
of the changeover is good this method can work well In practice though it is difficult to set the
necessary timing to operate correctly and disconnectionreconnection of the supply can cause
significant voltagecurrent transients
In Open transition there are Four states
23 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 OFF State All Contactors are open
2 Star State The Main [KM3] and the Star [KM1] contactors are closed and the delta [KM2]
contactor is open The motor is connected in star and will produce one third of DOL torque at one
third of DOL current
3 Open State This type of operation is called open transition switching because there is an
open state between the star state and the delta state The Main contractor is closed and the Delta
and Star contactors are open There is voltage on one end of the motor windings but the other end
is open so no current can flow The motor has a spinning rotor and behaves like a generator
4 Delta State The Main and the Delta contactors are closed The Star contactor is open The
motor is connected to full line voltage and full power and torque are available
(2) Closed Transition StarDelta Starter
There is a technique to reduce the magnitude of the switching transients This requires the use of a
fourth contactor and a set of three resistors The resistors must be sized such that considerable
current is able to flow in the motor windings while they are in circuit
The auxiliary contactor and resistors are connected across the delta contactor In operation just
before the star contactor opens the auxiliary contactor closes resulting in current flow via the
resistors into the star connection Once the star contactor opens current is able to flow round
through the motor windings to the supply via the resistors These resistors are then shorted by the
delta contactor If the resistance of the resistors is too high they will not swamp the voltage
generated by the motor and will serve no purpose
In closed transition the power is maintained to the motor at all time This is achieved by
introducing resistors to take up the current flow during the winding changeover A fourth
contractor is required to place the resistor in circuit before opening the star contactor and then
removing the resistors once the delta contactor is closed These resistors need to be sized to carry
the motor current In addition to requiring more switching devices the control circuit is more
complicated due to the need to carry out resistor switching
In Close transition there are Four states
1 OFF State All Contactors are open
2 Star State The Main [KM3] and the Star [KM1] contactors are closed and the delta [KM2]
contactor is open The motor is connected in star and will produce one third of DOL torque at one
third of DOL current
Star Transition State The motor is connected in star and the resistors are connected across the
delta contactor via the aux [KM4] contactor
24 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Closed Transition State The Main [KM3] contactor is closed and the Delta [KM2] and Star
[KM1] contactors are open Current flows through the motor windings and the transition resistors
via KM4
Delta State The Main and the Delta contactors are closed The transition resistors are shorted out
The Star contactor is open The motor is connected to full line voltage and full power and torque
are available
Effect of Transient in Starter (Open Transient starter)
It is Important the pause between star contactor switch off and Delta contactor switch is on correct
This is because Star contactor must be reliably disconnected before Delta contactor is activated It
is also important that the switch over pause is not too long
For 415v Star Connection voltage is effectively reduced to 58 or 240v The equivalent of 33
that is obtained with Direct Online (DOL) starting
If Star connection has sufficient torque to run up to 75 or 80 of full load speed then the motor
can be connected in Delta mode
When connected to Delta configuration the phase voltage increases by a ratio of V3 or 173 The
phase currents increase by the same ratio The line current increases three times its value in star
connection
During transition period of switchover the motor must be free running with little deceleration
While this is happening ldquoCoastingrdquo it may generate a voltage of its own and on connection to the
supply this voltage can randomly add to or subtract from the applied line voltage This is known as
transient current Only lasting a few milliseconds it causes voltage surges and spikes Known as
a changeover transient
Size of each part of Star-Delta starter
(1) Size of Over Load Relay
For a star-delta starter there is a possibility to place the overload protection in two positions in the
line or in the windings
Overload Relay in Line
In the line is the same as just putting the overload before the motor as with a DOL starter
The rating of Overload (In Line) = FLC of Motor
Disadvantage If the overload is set to FLC then it is not protecting the motor while it is in delta
(setting is x1732 too high)
Overload Relay in Winding
25 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
In the windings means that the overload is placed after the point where the wiring to the contactors
are split into main and delta The overload then always measures the current inside the windings
The setting of Overload Relay (In Winding) =058 X FLC (line current)
Disadvantage We must use separate short circuit and overload protections
(2) Size of Main and Delta Contractor
1 There are two contactors that are close during run often referred to as the main contractor and
the delta contactor These are AC3 rated at 58 of the current rating of the motor
Size of Main Contactor= IFL x 058
(3) Size of Star Contractor
The third contactor is the star contactor and that only carries star current while the motor is
connected in star The current in star is 1 radic3= (58) of the current in delta so this contactor can
be AC3 rated at one third (33) of the motor rating
Size of Star Contactor= IFL x 033
Motor Starting Characteristics of Star-Delta Starter
Available starting current 33 Full Load Current
Peak starting current 13 to 26 Full Load Current
Peak starting torque 33 Full Load Torque
Advantages of Star-Delta starter
The operation of the star-delta method is simple and rugged
It is relatively cheap compared to other reduced voltage methods
Good TorqueCurrent Performance
It draws 2 times starting current of the full load ampere of the motor connected
Disadvantages of Star-Delta starter
Low Starting Torque (Torque = (Square of Voltage) is also reduce)
Break In Supply ndash Possible Transients
Six Terminal Motor Required (Delta Connected)
It requires 2 set of cables from starter to motor
It provides only 33 starting torque and if the load connected to the subject motor requires higher
starting torque at the time of starting than very heavy transients and stresses are produced while
changing from star to delta connections and because of these transients and stresses many
electrical and mechanical break-down occurs
26 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
In this method of starting initially motor is connected in star and then after change over the motor
is connected in delta The delta of motor is formed in starter and not on motor terminals
High transmission and current peaks When starting up pumps and fans for example the load
torque is low at the beginning of the start and increases with the square of the speed When
reaching approx 80-85 of the motor rated speed the load torque is equal to the motor torque and
the acceleration ceases To reach the rated speed a switch over to delta position is necessary and
this will very often result in high transmission and current peaks In some cases the current peak
can reach a value that is even bigger than for a DOL start
Applications with a load torque higher than 50 of the motor rated torque will not be able to start
using the start-delta starter
Low Starting Torque The star-delta (wye-delta) starting method controls whether the lead
connections from the motor are configured in a star or delta electrical connection The initial
connection should be in the star pattern that results in a reduction of the line voltage by a factor of
1radic3 (577) to the motor and the current is reduced to 13 of the current at full voltage but the
starting torque is also reduced 13 to 15 of the DOL starting torque
The transition from star to delta transition usually occurs once nominal speed is reached but is
sometimes performed as low as 50 of nominal speed which make transient Sparks
Features of star-delta starting
1 For low- to high-power three-phase motors
2 Reduced starting current
3 Six connection cables
4 Reduced starting torque
5 Current peak on changeover from star to delta
6 Mechanical load on changeover from star to delta
Application of Star-Delta Starter
The star-delta method is usually only applied to low to medium voltage and light starting
Torque motors
The received starting current is about 30 of the starting current during direct on line start and the
starting torque is reduced to about 25 of the torque available at a DOL start This starting
method only works when the application is light loaded during the start If the motor is too heavily
27 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
loaded there will not be enough torque to accelerate the motor up to speed before switching over
to the delta position
LESSON 1 WIRING SYSTEM OF SINGLE PHASE DISTRIBUTION BOARD
Introduction
28 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
29 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
30 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
31 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 2 WIRING SYSTEM OF SINGLE PHASE LIGHTING CIRCUIT Introduction
Objectives
1 Identify component and the specification
2 Wire component according to the schematic diagram
3 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Wiring bay Perforated metal 180 cm x 180 cm 1
2 Cut out fuse 63 A 240 V 1
3 Neutral link 1
4 Single pole one way switch cw
switch box
5A 240Vac 4
5 single pole two way switch cw
switch box
5A 240Vac 2
6 RCCB In = 40 A Tripping current
100mA240 Vac 50 Hz
1
7 Main switch 32 A 240V 1
8 kWatthour meter 40 A 240 Vac 1
9 Single pole MCB 6A 240 Vac 1
10 Self tapping Wood screw As required
11 DIN rail 35 mm width As required
32 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
12 PVC trunking 50 mm x 50 mm As required
13 Terminal blocks 5 A As required
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
1 One way switch to control one lamp
2 One way switch to control two lamps
3 Two of two way switch to control one lamp
4 Two of single pole two way switch and one of an intermediate switch to control one
lamp
5 One unit of ceiling fan and fan regulator to be controlled by one way switch
4 Test the functionality of completed project
LESSON 3ndash WIRING SYSTEM OF SINGLE PHASE POWER CIRCUIT Introduction
33 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
34 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify types of component and its specification
2 Wire component according to the schematic diagram given
3 Test the functionality of the circuit dead circuit test life circuit test
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board Perforated Metal 1
2 kWh meter 240 V 40 A 1
3 Socket outlet 13A 240Vac 4
4 RCCB 40A Trip Amps
30mA240 Vac
1
5 3 pin socket 240Vac 13A 4
6 Single pole MCB 20A 240 V 2
7 DOL starter 1 kW 240Vac 2
8 1 phase induction motor 2Hp 240 Vac 1
9 Cooker control unit 4kW 240Vac 1
10 Water heater point 4kW 240 Vac 1
11 DIN rail 35 mm As required
12 PVC casing 20mm As required
13 Flexible wires 05 mm As required
14 Terminal block 10 A As required
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Wire two unit of 13 A socket outlet in radial circuit
3 Wire four units of 13 A socket outlet in ring circuit
4 Wire one unit DOL starter for air-conditioner point
5 Wire one unit of cooker control unit point
6 Wire one unit of water heater point
7 Test the functionality of each component by using mmeter or power supply whichever
applicable
8 Wire component according to circuit diagram
9 Test the functionality of completed project dead circuit test life circuit test
Note
35 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Ensure that the correct rating of protection device and size of wire used
LESSON 4ndash CONDUIT BENDING AND TRUNKING FABRICATION TECHNIQUE
Common fitting used in an industrial wiring
Cutting and threading the condute
36 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
37 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
38 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify conduit fitting and the specification
2 Measure and Cut steel conduit according to specified dimension
3 Bend and fabricate conduit at 45 90 according to layout diagram
4 Wire component according to the schematic diagram
5 Test the functionality of the circuit
39 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Conduit Bender Oslash 19 mm ( frac34 ldquo) 1
2 Measuring Tape 3 metre 1
3 Hacksaw frame and blade 30cm 1
4 Conduit cutter 1
5 Pipe Vise 1
6 Pipe Wrench 1
7 Ratchet Dies 20 mm 1
8 Metal trunking 50 mm x 50 mm 1
9 GI conduit 20mm 1
10 End box 20 mm 1
11 Flexible wires 05 mm As required
12 Connectors 5 A As required
13 Single core PVC ins Cable 25 mm 2 As required
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Wire two unit of 13 A socket outlet in radial circuit
3 Wire four unit of 13 A socket outlet in ring circuit
4 Wire one unit DOL starter for air-conditioner point
5 Wire one unit of cooker control unit point
6 Wire one unit of water heater point
7 Test the functionality of each component by using multimeter or power supply whichever
applicable
8 Wire component according to circuit diagram
9 Test the functionality of completed project
Note
Ensure that the rating of protection device and size of wire
K prior to 31 March
2004 (BS 7671)
(formerly)
bare conductor
sleeved at terminations (formerly)
40 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 5 ndashWIRING SYSTEM OF 1 Oslash LIGHTING AND POWER CIRCUIT
POWER CIRCUITSa Radial circuits
Radial circuits are arranged in the same way as item 1 above in lighting layouts in that each socket
outlet is supplied via the previous one
Points to note
1 The number of socket outlets complying with BS 1363 is unlimited for a floor area of up to 50m 2 if
the circuit protection is a 30 A or 32 A cartridge fuse or circuit breaker the cable being 4 mm PVC
copper or 25 mm2 mineral insulated (mi)
2 The number of socket outlets is unlimited for a floor area up to 20 m 2 with any type of circuit
protection of 20 A using 25 mm2 PVC copper cable or 15 mm2 mi
3 The total number of fused spurs is unlimited
b ring final circuits
These circuits are the same as radial circuits except that the final socket outlet is wired back to the
supply position In effect any outlet is supplied from two directions (Fig 152)
Points to note
1 Every twin-socket outlet counts as two single-socket outlets
2 The number of non-fused spurs must not exceed the total number of points on the ring Fig 158
shows seven points on the ring and five spurs
3 The fuse rating of a fused spur box must not exceed 13 A and the current rating of all points supplied
by the fused spur must not exceed 13 A
4 Non-fused spurs must supply no more than one single or one double socket on the ring Fig 158
shows seven points on the ring and five spurs rating of all points supplied by the fused spur must not
exceed 13 A or one stationary appliance
CapacityMain conductor size
copper (mm2)
Earth conductor
size (mm2)
Circuit breaker
capacity (A)
Up to 600 W 15 15 6
600ndash1200 W 1525 15 10
1200ndash1800 W 254 25 16
41 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Ring circuit
(floor area 100 m2)25 15 3032
A2 radial circuit
(floor area 75 m2)40 25 3032
A3 radial circuit
(floor area 50 m2)25 15 20
Air conditioner (15 tonne) 60 60 3032
Cooker 60 60 3032
Water heater 40 40 20
Objectives
1 Identify component and the specification
2 Wire component according to the schematic diagram
3 Test the functionality of the circuit
42 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board Perforated 1
2 Cut out fuse and neutral link 60A 240V 1each
3 kWh meter 240V 40A 1
4 Switched Socket outlet 13A 240Vac 4
5 Single pole two way switch cw switch
box
5A 240Vac 2
6 RCCB ELCB 63 A Tripping current 100mA
415 Vac
1
7 3 pin plug 240Vac 13A 4
8 Single pole MCB 20 A 2
9 Single pole MCB 6A 1
10 Single pole MCB 20A 2
11 DOL starter 240Vac 2
12 1 phase induction motor 2hp 240 Vac 1
13 Self tapping Wood screw As required
14 DIN rail Stainless steel allum35 mm As required
15 PVC pipe 20mm dia As required
16 End box 20 mm dia 4
17 Flexible wires 05 mm 2 As required
18 Connectors 5 A As required
Procedures
43 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
4 Test the functionality of completed project
LESSON 6 ndash WIRING SYSTEM OF 3 Oslash DISTRIBUTION BOARD
Introduction
44 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
45 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
46 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
47 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
48 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify each component and the specification
2 Wire component according to the schematic diagram given
3 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting Board 450 x 600 mm Perforated metal 1
2 5 pin round socket and plug 415V ac 32A 1
3 Cut out fuse 60 A 3
4 Neutral link 1
5 kWatt hour meter 415V 60A 1
6 ELCB RCCB 3P+N In=63A415 Vac I trip= 300mA 1
7 ELCB RCCB 3P+N In=63A415 Vac I trip= 30mA 1
8 Single pole MCB 6A 240 V 3
9 Single pole MCB 20A 240 V 3
10 DOL starter 20 A 240Vac 2
11 Socket outlet 15 A 240 Vac 1
12 Switched Socket outlet 13 A 240 Vac 3
13 Led indicating light 5A 240 Vac 3
14 Single pole 4 gang 1 way switch 5A 240 Vac 2
15 Single pole 2 way switch 5A 240 Vac 2
16 1 phase induction motor 1 kW 240Vac 1
17 Metal trunking 30 mm x30 mm As required
18 Self tapping Wood screw 4 mm x 20 mm As required
19 DIN rail 25 mm x 1mm
20 GI steel rigid conduit 20mm As required
21 Flexible conduit 20mm As required
22 End box 20 mm 4
23 Flexible wires 05 mm 2 As required
24 Single core PVC insulated wire 15 mm 2 As required
25 Single core PVC insulated wires 25 mm 2 As required
26 Terminal block 10 A As required
Procedures
49 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify each components and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
4 Test the functionality of completed project
1 dead circuit test
2 life circuit
Note Proper earthing should be made
50 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 7 ndash WIRING SYSTEM OF THREE PHASE LIGHTING AND POWER CIRCUIT
51 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
52 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify component and the specification
2 Wire component according to the schematic diagram
3 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting bay Board Perforated metal 180 cm x 180 cm 1
2 k Watt hour meter 415V 60A 1
3 MCCB 415V 60A
4 ELCB RCCB In=60A415 Vac I trip=30mA 1
5 5 pin round Socket and
plug
415Vac 32A 4
6 Single pole MCB 6A 1
7 Triple pole MCB 20A 2
8 Triple pole Main switch 60A 1
9 DOL starter 240Vac 2
10 3 phase induction motor 2hp 415 Vac 1
11 1 phase induction motor 1
12 Metal trunking 30 mm x30 mm As required
13 Self tapping Wood screw 4 mm x 20 mm As required
14 DIN rail 25 mm x 1mm
15 GI steel rigid conduit 20mm As required
16 Flexible conduit 20mm As required
17 End box 20 mm 4
18 Flexible wires 05 mm As required
19 Connectors 10 A As required
Procedures
1 Identify each components and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
4 Test the functionality of completed project
1 dead circuit 2 life circuit test
5 Record the current drawn by the load as connected in star and delta
Note Proper earthing should be made
53 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 8 INSPECTION AND TESTING OF ELECTRICAL INSTALLATION
On completion of a wiring installation a number of tests on the installation have to be conducted to
ascertain that the wiring circuits and connected appliances are safe for use Prior to carrying out the
tests an inspection has to be done The results of the inspectionsupervision and test have to be
presented in Form G (as in Appendix IV) and Form H (as in Appendix V)
To have the test certification as in Form H the following tests shall be conducted
i Continuity Test
ii Insulation Resistance Test
iii Polarity Test
iv Earth Electrode Resistance test and
v Residual Current Device Test
1 Continuity Test
There are 3 main types of continuity tests for the final circuits-
i Protection Conductor Continuity Test
ii Final Ring Circuit Conductor Continuity Test
iii Live and Neutral Conductor Continuity Test
a) Protection Conductor Continuity Test
bull To ascertain that all protection conductors are connected in the correct and effective manner
bull Test equipment ndash Multimeter (Ohm range) or Ohm meter
54 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
bull Test Method
1 1048766 Ensure that the main switch RCD and MCB are open circuited (switched off) and all loads
are disconnected
2 1048766 Connected the test leads as in the Figure 81 The meter reading shall be less than 1 Ω
55 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Final Ring Circuit Conductor Continuity Test
bull To ensure that all conductors around the ring circuit have continuity
bull Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
bull Test Method
1 1048766 Disconnect both the supply source live conductors from the MCB the neutral conductor
from the neutral terminals and the earth conductor from the earth terminal in the distribution
fuse box
2 1048766 Connect the test leads as in the Figure 82 (EE)
3 1048766 Repeat the procedure for (L-L) and (N-N)
4 1048766 The meter reading value shall be less than 1 ohm
56 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Live and Neutral Conductor Continuity Test
a To ensure that each conductor in the circuit has continuity
b Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
2 Test Method
1 1048766 Switch off the Main switch RCD and MCB
2 1048766 Disconnect all loads
3 1048766 Switch on all switches in the circuit
4 1048766 Disconnect the fusesfinal circuit breakers and close the circuit
5 1048766 Carry out the test as shown in Figure 83
6 1048766 The meter reading value shall be less than 1Ω
57 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
58 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
CONTINUITY TEST
Insulation Resistance Test
i Ensure that there is no leakage current between phase conductors phase and neutral conductors and
phase conductor and earth
ii Test the strength of the cable insulation
iii Test Equipment ndash Insulation Resistance Tester operating voltage is 250VDC or 500VDC
iv Test Method
1 1048766 Switch off main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
59 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
4 1048766 Carry out test as in the Table below
5 1048766 Meter reading value shall be less than 1 Megaohm
60 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
61 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Insulation resitance test
62 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
INSULATION RESISTANCE TEST BETWEEN CONDUCTORS AND OPPOSITE POLARITY
Polarity Testi Ensure that each fuse or single pole control and protection device is connected only in the phase
conductor
ii Intermediate contact of Edison screw lamp holder is connected to the phase conductor
iii Ensure that phase neutral and earth conductors at socket outlets are connected at the correct
terminals
iv Test Equipment ndash Multimeter (Ohm range) or Ohm meter
v Test Method
1 1048766 Switch off Main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in Figure 85
63 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
5 1048766 Test switches and single phase control devices at the phase conductors
6 1048766 Test socket outlet connection sources
7 1048766 Test Edison screw lamp holder connections
8 1048766 Meter reading value shall be less than 1 Ω
64 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Polarity test
65 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Earth Electrode Resistance Testi To test the earth electrode resistance
ii To ascertain the suitability of the location of the electrode
iii To ensure that the electrode is not buried within the resistance area of another electrode
iv Test equipment ndash Earth Resistance Tester
v Test method -
1 1048766 Terminal rsquoErsquo is connected to the electrode to be tested (green conductor)
2 1048766 Terminal lsquoPrsquo is connected to the potential spike (yellow conductor) at a distance of 10
meters from the earth electrode
3 1048766 Terminal lsquoCrsquo is connected to the current spike (red conductor) at a distance of 20 meters
from the earth electrode
Earth Electrode Resistance Measurement Method (Figure 86)
This test must be repeated at least three times to ensure that the reading is not affected by interacting
earthing regions
i Record the first reading (Z1) Example Z1 = 10 Ω
ii Move the voltage spike to a distance of 6 meters from the original position Record the second
reading (Z2 ) Example Z2 = 10 Ω
iii Move the voltage spike to a distance of 6 meters from the original position Record the third
reading (Z3) Example Z3 = 10 Ω
66 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Residual Current Device Testi Ensure that the residual current device (RCD) trips within the set time on the occurrence of current
leakage to earth
ii Test Equipment ndash RCD Tester RCCB Tester
iii Test Method 1
1 1048766 Use the Trip Test Button
2 1048766 Press the trip button found on the RCD to determine if it trips or otherwise This test would
not be able to determine the sensitivity of the RCD nor the time taken for it to trip
iv Test Method 2
i 1048766 Use a RCD Tester
ii This equipment is equipped with a 13A plug which can be connected to a 13A socket outlet
Select the RCD sensitivity to be the same as the sensitivity of the RCD to be tested to
determine if the RCD can trip The time to trip shall not exceed 40 mS
iii 1048766 Test method ndash
a) Position the selection switch in accordance with the sensitivity of the RCD used
Example 100 mA 01 A
b) Position the operations switch to lsquoNo Triprsquo (frac12 Rated mA = 50) connect the 3 pin plug to
the 13A socket outlet
67 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
c) Switch on the 13A socket outlet ndash ensure that the P-N and P-E lights light up
This shows that the polarity is correct (Note if both the lights as above do not light up the test cannot
be continued)
d) Press the test button ndash the reading shows less than 200 mS and simultaneously the lsquotestrsquo light lights
up and the P-N and P-E lights do not light up At that instant the RCD will not trip
e) Move the selection switch to 180o (+ve wave) ndash repeat steps (d) and (e) Move the operations
switch to lsquoTriprsquo (Rated mA = 100)
g) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200mS
h) Move the selection switch to 0o (-ve wave)
i) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
j) The above test is repeated until a near correct reading is obtained
k) Record the test results
l) Change the operations switch to lsquoFast Triprsquo and press the test button ndash RCD will trip within a
time not exceeding 40 millisecond
m) Repeat a number of times at 0o or 180o
On completion of a wiring installation a number of tests on the installation have to be conducted to
ascertain that the wiring circuits and connected appliances are safe for use Prior to carrying out the
tests an inspection has to be done the following tests shall be conducted
i Continuity Test
ii Insulation Resistance Test
iii Polarity Test
iv Earth Electrode Resistance test and
v Residual Current Device Test
821 Continuity Test
There are 3 main types of continuity tests for the final circuits-
i Protection Conductor Continuity Test
ii Final Ring Circuit Conductor Continuity Test
68 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
iii Live and Neutral Conductor Continuity Test
a) Protection Conductor Continuity Test
bull To ascertain that all protection conductors are connected in the correct and effective manner
bull Test equipment ndash Multimeter (Ohm range) or Ohm meter
bull Test Method
1 1048766 Ensure that the main switch RCD and MCB are open circuited (switched off) and all loads are
disconnected
2 1048766 Connected the test leads as in the Figure 81
3 1048766 The meter reading shall be less than 1 Ω
Final Ring Circuit Conductor Continuity Test
bull To ensure that all conductors around the ring circuit have continuity
bull Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
bull Test Method
1 1048766 Disconnect both the supply source live conductors from the MCB the neutral conductor
from the neutral terminals and the earth conductor from the earth terminal in the distribution
fuse box
2 1048766 Connect the test leads as in the Figure 82 (EE)
3 1048766 Repeat the procedure for (L-L) and (N-N)
4 1048766 The meter reading value shall be less than 1 ohm Figure 82 - Final Ring Circuit Conductor
Continuity Test Ohm Meter
Disconnect both the supply source cables from mcbfuse
Take readings at earth conductors of both sources and note resistance readings
Live and Neutral Conductor Continuity Test
1 To ensure that each conductor in the circuit has continuity
2 Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
3 Test Method
1 1048766 Switch off the Main switch RCD and MCB
2 1048766 Disconnect all loads
3 1048766 Switch on all switches in the circuit
4 1048766 Disconnect the fusesfinal circuit breakers and close the circuit
5 1048766 Carry out the test as shown in Figure 83
6 1048766 The meter reading value shall be less than 1 ohm Figure 83 - Live and Neutral
Conductor Continuity Test Ohm Meter
Insulation Resistance Test
69 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
i Ensure that there is no leakage current between phase conductors phase and neutral conductors and
phase conductor and earth
ii Test the strength of the cable insulation
iii Test Equipment ndash Insulation Resistance Tester Operating voltage is 250VDC or 500VDC
iv Test Method
1 1048766 Switch off main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in the Table below
5 1048766 Meter reading value shall be less than 1 Megaohm
Polarity Test
i Ensure that each fuse or single pole control and protection device is connected only in the phase
conductor
ii Intermediate contact of Edison screw lamp holder is connected to the phase conductor
iii Ensure that phase neutral and earth conductors at socket outlets are connected at the correct
terminals
iv Test Equipment ndash Multimeter (Ohm range) or Ohm meter
v Test Method
1 1048766 Switch off Main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in Figure 85
5 1048766 Test switches and single phase control devices at the phase conductors
6 1048766 Test socket outlet connection sources
7 1048766 Test Edison screw lamp holder connections
8 1048766 Meter reading value shall be less than 1 Ω
Earth Electrode Resistance Test
i To test the earth electrode resistance
70 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
ii To ascertain the suitability of the location of the electrode
iii To ensure that the electrode is not buried within the resistance area of another electrode
iv Test equipment ndash Earth Resistance Tester
v Test method -
1 1048766 Terminal rsquoErsquo is connected to the electrode to be tested (green conductor)
2 1048766 Terminal lsquoPrsquo is connected to the potential spike (yellow conductor) at a distance of 10
meters from the earth electrode
3 1048766 Terminal lsquoCrsquo is connected to the current spike (red conductor) at a distance of 20 meters
from the earth electrode E P C Electrode 10 meter 10 meter
Figure 86 ndash Earth Electrode Resistance Measurement Test Equipment
Earth Electrode Resistance Measurement Method (Figure 86)
This test must be repeated at least three times to ensure that the reading is not affected by interacting
earthing regions
i Record the first reading (Z1) Example Z1 = 10 Ω
ii Move the voltage spike to a distance of 6 meters from the original position Record the second
reading (Z2) Example Z2 = 10 Ω
iii Move the voltage spike to a distance of 6 meters from the original position Record the third
reading (Z3)
Example Z3 = 10 Ω
Residual Current Device Test
71 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
i Ensure that the residual current device (RCD) trips within the set time on the occurrence of current
leakage to earth
ii Test Equipment ndash RCD Tester RCCB Tester
iii Test Method 1
1 1048766 Use the Trip Test Button
2 1048766 Press the trip button found on the RCD to determine if it trips or otherwise This test would
not be able to determine the sensitivity of the RCD nor the time taken for it to trip
iv Test Method 2
1048766 Use a RCD Tester
This equipment is equipped with a 13A plug which can be connected to a 13A socket outlet Select the
RCD sensitivity to be the same as the sensitivity of the RCD to be tested to determine if the RCD can
trip The time to trip shall not exceed 40 mS
1048766 Test method ndash
a) Position the selection switch in accordance with the sensitivity of the RCD used
Example 100 mA 01 A
b) Position the operations switch to lsquoNo Triprsquo (frac12 Rated mA = 50) connect the 3 pin plug to
the 13A socket outlet
c) Switch on the 13A socket outlet ndash ensure that the P-N and P-E lights light up This shows that
the polarity is correct (Note if both the lights as above do not light up the test cannot be
continued)
d) Press the test button ndash the reading shows less than 200 millisecond and simultaneously the
lsquotestrsquo light lights up and the P-N and P-E lights do not light up At that instant the RCD will
not trip
e) Move the selection switch to 180o (+ve wave) ndash repeat steps (d) and (e) = 100)
f) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
g) Move the selection switch to 0o (-ve wave)
h) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
i) The above test is repeated until a near correct reading is obtained
j) Record the test results
k) Change the operations switch to lsquoFast Triprsquo and press the test button ndash RCD will trip within a
time not exceeding 40 mS
l) Repeat a number of times at 0o or 180o
72 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 9 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (DC)
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
73 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Start stop button 240Vac 5A 2
9 Filament lamp (Bulb ) 240Vac 40W 3
10 Overload Relay 415V 20A 3
11 Three phase induction motor 5 hp 3
12 Single phase step down transformer 2500VA 1
13 Single core PVC insulated Cable 1mm 2 As required
14 Single core PVC insulated Cable 25mm 2 As required
15 DIN rail 35 mm As required
16 PVC type Cable tray 50 mm x 50 mm As required
17 Cable ties 4 ldquo As required
18 Flexible wires 05 mm As required
19 PVC Connectors 5 A amp 20 A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the schematic
diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a optional exercise
i Simple DOL starter
ii Forward reverse DOL starter
iii Forward Reverse Dahlander motor
iv Three motors operated in sequence by DOL starter operated by manual push
button or time delay relay
74 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
a One loop per-cycle
b Continuous operation in a loop
c optional circuit design to represent the same task
v Only one out of three motors to be operated at a time (quiz)
4 Test the functionality of completed project
LESSON 10 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (AC)
75 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 1
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Lamp point 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
76 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
11 Overload Relay 415V 20A 3
12 Three phase induction
motor
5 hp 3
13 Single core PVC insulated
Cable
1mm 2 As required
14 Single core PVC insulated
Cable
25mm 2 As required
15 DIN rail 35 mm As required
16 PVC type Cable tray 50 mm x 50 mm As required
17 Cable ties 4 ldquo As required
18 Flexible wires 05 mm As required
19 PVC Connectors 5 A amp 20 A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the
schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram optional exercise
4 Simple DOL starter
5 Forward reverse DOL starter
6 Test the functionality of completed project
77 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 1
78 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
cm
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Indicating light 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
11 Overload Relay 415V 20A 3
12 Three phase induction motor 5 hp 3
13 Single phase step down
transformer
2500VA 1
14 Single core PVC insulated
Cable
1mm 2 As required
15 Single core PVC insulated
Cable
25mm 2 As required
16 DIN rail 35 mm As required
17 PVC type Cable tray 50 mm x 50 mm As required
18 Cable ties 4 ldquo As required
19 Flexible wires 05 mm As required
20 PVC Connectors 5 A amp 20 A 240 V As required
21 Single pole MCB 6A 240 V 1
22 Single pole MCB 2A 240 V 1
23 Triple pole MCB 20A 415 V 1
24 Mounting board 30 cm x 40 cm x 3
cm
1
25 Relay cw 11 pin socket 10 A 240 Vac 2
26 Time delay relay 10 A 240 Vac 3
27 Triple pole Contactor 20A 240Vac 3
28 Batten type Lamp holder 240Vac 10 A 3
29 Start stop button 240Vac 10A 2
30 Indicating light (Bulb ) 240Vac 25W 3
31 Overload Relay 415V 20A 1
32 Three phase dahlander type
induction motor
5 hp 1
33 Single phase step down
transformer
24024Vac
2500VA
1
79 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
34 Single core PVC insulated
Cable
1mm 2 As required
35 Single core PVC insulated
Cable
25mm 2 As required
36 DIN rail 35 mm As required
37 PVC type Cable tray 50 mm x 50 mm As required
38 Cable ties 4 ldquo As required
39 Flexible wires 075 mm As required
40 PVC Connectors 5 A amp 20 A 240 V As required
41 Terminal block 20A 240Vac As required
Procedures
5 Identify each component according to specification and quantity required from the schematic
diagram attached
6 Test the functionality of each component by using multi-meter or power supply whichever
applicable
7 Wire component according to circuit diagram
8 Three motors operated in sequence by DOL starter operated by manual push button or time
delay relay
a One loop per-cycle
b Continuous operation in a loop
c optional circuit design to represent the same task
d Only one out of three motors to be operated at a time (quiz)
9 Test the functionality of completed project
80 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
BASIC DESIGN INDUSTRIAL MOTOR CONTROL (SEQUENCE CONTROL)
THREE PHASE INDUCTION MOTOR OPERATED IN SEQUENCE BY DIRECT ON LINE
STARTER
LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
81 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
82 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Lcd lamp indicator 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
11 Overload Relay 415V 20A 3
12 Three phase induction motor 5 hp 3
13 Single phase step down transformer 2500VA 1
14 Single core PVC insulated Cable 1mm 2 As required
15 Single core PVC insulated Cable 25mm 2 As required
16 DIN rail 35 mm As required
17 PVC type Cable tray 50 mm x 50 mm As required
18 Cable ties 4 ldquo As required
19 Flexible wires 1 mm Oslash As required
20 PVC Terminal block 10A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the schematic
diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a optional exercise
i Forward Reverse dahlander motor
4 Test the functionality of completed project
83 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
THREE PHASE DAHLANDER TYPE INDUCTION MOTOR OPERATED FORWARD AND
REVERSE OPERATION BY DIRECT ON LINE STARTER
84 ndash 99EASYTECH ENTERPRISE
LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
Introduction
If a motors windings are connected in the star configuration any two phases will be in series across
the supply and hence the line current will be smaller(by 577) than if the windings were connected in
the delta arrangement
Hence larger-type motors with heavy starting currents are first connected in star and then when the
starting currents fall in delta This of course means that all six of the ends of the windings must be
brought to terminations outside the casing (Fig 833)
EZTECH
EZTECH ELECTRICAL INSTALLATION GUIDE
The automatic version of this starter incorporates a timing relay which automatically changes the
connections from star to delta Figs 834 and 835 show the wiring and schematic diagrams for a star
delta starter
Objectives
1 Identify component and the specification
2 Design forward reverse star delta starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
2 ndash 99EASYTECH ENTERPRISE
REV -C
LEGENDMCCB Moulded Case Circuit BreakerTOR Thermal Over Load RelayFOW-C Mains Forward ContactorREV-C Mains Reverse ContactorDC Delta ContactorSC Star ContactorS-SW Mains Selector Switch
SC
V2
W2
U2
DC
V1
W1
U1
TOR
TOR
FOW-C
30A MCCB
TOR
MAIN CIRCUIT FORWARD REVERSE STAR DELTA
RYBN S
-SW
3 PHASEINDUCTION MOTOR
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Relay 10 A 240V 3
5 Triple pole Contactor
6 cw NO NC auxiliary contact
240Vac 20 A 4
7 Overload Relay 415 V 1
8 LED indicator 240vac 5 A 4
9 Start stop button 240Vac 5A 2
10 DIN rail 35 mm As required
11 Flexible wires 1 mm As required
12 Single core PVC insulated
wire
25 mm As required
13 Terminal block 20 A As required
14 Squirrel cage motor 5kW 1
15 5 pin plug and socket 415V 20A 1
16 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
3 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
a Manual star delta
b Manual Forward reverse star delta starter
c Automatic star delta starter
d Automatic Forward reverse star delta starter
4 Test the functionality of completed project
4 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
Objectives
1 Identify component and the specification
2 Design auto transformer starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
5 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Autotransformer starter is used to start a 3 phase induction motor that has a rating between 10 to 15 hp
6 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Autotransformer set 10Kw 415 V 50 Hz 1
5 Triple pole Contactor 240Vac 4
6 Batten type Lamp holder 240 Vac 105 A 4
7 Start stop button 240Vac 10A 4
8 Filament lamp (Bulb ) 240Vac 40W 4
9 DIN rail 35 mm As required
10 Flexible wires 1 mm As required
7 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
11 Single core PVC insulated
wire
25 mm As required
12 Terminal block 20 A As required
13 Squirrel cage motor 10kW 1
14 5 pin plug and socket 415V 20A 1
15 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a open transient autotransformer starter
b close transient autotransformer starter
c Forward reverse autotransformer starter
4 Test the functionality of completed project
8 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
Objectives
1 Identify component and the specification
2 Design rotor resistance starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
9 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Rotor Resistor set 10kW 1
5 Triple pole Contactor 240Vac 20A 4
6 Indicating light 240vac 5 A 4
7 Start stop push button 240Vac 5A 4
8 DIN rail 35 mm As required
9 Flexible wires 1 mm 2 As required
10 Single core PVC insulated wire 25 mm 2 As required
11 Terminal block 20 A As required
12 Slip Ring motor 10kW 1
13 5 pin round 3 phase socket 415V 20A 1
14 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
10 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
4 Test the functionality of completed project
a Dead circuit test b Life circuit test
5 Measure starting and running Amps
LESSON 16
TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
An installation in general will suffer damage
Damage usually occurs on the electric motor control as follows
1 Damage to the main circuit
2 Damage to the control circuit
The cause of the damage
i Overcurrent overload short circuit
ii Leakage current to ground
iii Equipment malfunction
iv The main control circuit
a Trip of main circuit protection devices fire
b Defect of motor terminal such as short circuit fire loose
v The control circuit is not functioning -
a contactor relay relay time overload relay does not work damaged burned
b Loose cable connection disconnected
Detecting and Repairing Damage
Examples of damage are as follows
i Motor does not work
ii Motor function and overload relay trips
iii Motor function but only partially functional control circuit
Methods of detecting damage
Among the known methods necessary to detect damage are as follows
1 Turn off the electricity at the main switch (main switch) in order to avoid any danger during the
work carried out to detect damage
2 Check all the protective gear that controls the motor control main circuit
11 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
3 Make sure the damage function control circuit
4 Check the control circuit according to the schematic circuit diagram of the motor control
5 Check the operation of the control circuit
Note
Use wiring that has been installed on the SYSTEM OF MOTOR CONTROL BOARD by Forward
Reverse control circuit for Star Delta to test and look for damage
SELF-ASSESSMENT QUESTIONS
1 (a) Explain what is meant by the term lsquoback emfrsquo in a motor
(b) Outline the basic differences between series shunt and compound wound dc motors
2 (a) With the aid of diagrams explain how the speed of series shunt and compound-wound motors
may be controlled
(b) A 440V dc shunt-wound motor has a field resistance of 200R and an armature resistance of 06 R
When its speed is 20 rev d second the current drawn from the supply is 122A Calculate its back
emf at this speed If the speed were decreased to 19 revssecond the field flux remaining unchanged
calculate the new back emf and the new armature current
3 A load of 64 kW at 240 V is supplied from the terminals of a shunt-wound dc generator The field
resistance is 180 A Calculate the armature current
4 (a) Explain with the aid of a diagram how a rotating magnetic field may be
(b) What is meant by lsquosynchronous speedrsquo
Calculate the synchronous obtained speed of a 12 pole motor if the supply frequency is 50Hz
5 (a) Explain the action of a synchronous motor
(b) What methods are available to start a synchronous motor Explain with diagrams
6 (a) Explain the action of a cage induction motor
(b) What is meant by the term lsquosliprsquo
Calculate the percentage slip of a six pole induction motor running at 162 revssecond from a 50 Hz
supply
7 Describe with sketches three different ways of starting a single-phase induction motor
12 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
8 Explain with the aid of a sketch the action of a three-phase DOL starter
What are dashpots used for How are remote start and stop buttons connected
9 A I0 kW 240V 50Hz single-phase cage rotor induction motor is 85efficient and has a PF of 068
lagging Calculate the motor current and the value of capacitor required to raise the PF to 093
lagging
10 Calculate the torque developed by an 18 kW four-pole induction motor run at 35 slip from a
50Hz supply
APPENDIX 1
13 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 11
14 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 111
Attachment Reference
httpswwwtlc-directcoukBook621htm
httpwwwstgovmyindexphpms
15 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Legal Requirements
Regulation 11(1) of the Electricity Regulations 1994 states that all wiring or rewiring of an
installation or extension to an existing installation which shall be carried out by an Electrical
Contractor or a Private Wiring Unit have to obtain the approval in writing from a licensee or supply
authority
1 Planning of Electrical Wiring Work
Prior to carrying out wiring work the wiremancontractor should plan and determine the tasks to be
undertaken so that the work carried out is tidy neat and safe to be used The wiremancontractor shall
-i Undertake a site visit
5 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
ii Determine the consumer load requirements
iii Calculate the maximum load demand and
iv Submit the plans drawings and specifications
The planning flow chart for building wiring installations is as shown in Figure 31
11 Site Visit
The purpose of the site visit is to determine -
i Electrical equipment suitable for use
ii Maximum load demand
iii Single or three phase incoming supply
iv Type of wiring and Equipment arrangement
Determining Consumer Load RequirementsWith the aid of the building floor plans the installation requirements such as the proposed load
placement of electrical equipment and installation design plans can be determined
11 Calculating Maximum Load Demand
The estimate of the maximum load demand is for determining the specifications of the wiring
equipment such as the cables and plans
According to clause 311 of MS IEC 60364 Part 1 to determine the maximum demand for each circuit
while ensuring an economic and reliable design within the permitted voltage drop limits Diversity
factors may be taken into account The maximum current demand calculations for each circuit must be
prepared These details will show the current requirements in amperes for each phase and also assist
in determining the cable sizes
Refer to the Third Schedule (Table A and Table B) and Regulation 11(2) of the Electricity Regulations
1994 to estimate the maximum current demand and the diversity factors that may be used for domestic
installations
12 Submission of the Plans Drawings and Specifications Regulation 65 of the Electricity
Regulations 1994 states that the eligibility to submit plans is as follows -
i Wireman with Single Phase Restriction ndash Low voltage single phase up to 60 A
ii Wireman with Three Phase Restriction ndash Low voltage up to 60A
6 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
2 CONTROL AND PROTECTION SYSTEM FOR ELECTRICAL WIRING
7 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
8 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
21 Selection of Control and Protection System for Electrical Wiring
Control and protection of a wiring is a system of separationisolation and switching together with the
protection system which are needed in every domestic wiring installation
22 Isolation and Switching
Examples of isolation and switching are switches power plugs socket outlets and circuit breakers
Their function is to manually connect and break the supply in a particular circuit without interfering
with other circuits
They also aim to prevent the danger of electrical shocks during maintenance testing fault finding and
repair works
23 Protection
This provides protection from dangers caused by electrical currents such as over current earth
leakage current short circuit lightning etc to the wiring system electrical equipment or consumer
The circuit below shows the isolation and protection devices which must be installed in a domestic
electrical wiring system
1 Current Protection
In general protection from the dangers of current can be divided into two aspects namely
i Overcurrent Protection (Over Load or Short Circuit) Properly rated circuit breakers or fuses suitable
for over load or short circuit protection must be used
9 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
The circuit breakers or fuses must be installed on the live conductors only For three phase circuits all
the circuit breakers or fuses must be combined in one set of circuits
Selection of over current devices must be based on the short circuit fault current levels of the circuit
breaker or main switch (kA)
ii Earth Leakage Current Protection
Properly rated Residual Current Devices (RCD) must be used for protection from earth leakage
currents (to prevent electric shocks)
a) Regulation 36(1) of the Electricity Regulations 1994 states that for a place of public entertainment
protection against earth leakage current must be provided by a residual current device of sensitivity
not exceeding 10 mA
b) Regulation 36(2) of the Electricity Regulations 1994 states that for a place where the floor is likely
to be wet or where the wall or enclosure is of low electrical resistance protection against earth leakage
current must be provided by a residual current device of sensitivity not exceeding 10 mA
c) Regulation 36(3) of the Electricity Regulations 1994 states that for an installation where hand-held
equipment apparatus or appliance is likely to be used protection against earth leakage current must be
provided by a residual current device of sensitivity not exceeding 30 mA and
d) Regulation 36(4) of the Electricity Regulations 1994 states that for an installation other than the
installation in (a) (b) and (c) protection against earth leakage current must be provided by a residual
current device of sensitivity not exceeding 100 mA
CABLE SELECTION
31 Selection of Wiring Cable Type
The selection of the cable size has to take into consideration the following-
i All wiring cables must be PVC or PVCPVC insulated with copper conductors Conductors with
cross sectional areas of 16mm2 or less must be of copper Aluminium conductors are not permitted
Refer to Table 4D1A in Appendix II for the current carrying capacities of copper conductor
ii Cables for swimming pools must be water resistant PE (polyethylene) insulated
10 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
iii The selected cable must be capable of delivering the electrical energy efficiently
iv The cable size allows it to carry the current without heating the cable
v The voltage drop must not exceed 4 of the supply voltage Refer to Table 4D1B in Appendix III
vi The cable insulation must be suitable for the surrounding conditions of the installation such as the
ability to withstand the surrounding temperatures and the ability to provide mechanical protection
vii Each conductor in the installation must be protected from overcurrent by means of overcurrent
protection devices needed to prevent damage to the cable insulation
32 Factors Related to Cable Current Carrying CapacityThe following factors in relation to the current carrying capacity of cables must be taken into
consideration-
i Surface wiring using clips ndash group factor
ii Wiring using conduits ndash space factor 40
iii Wiring using ducts ndash space factor 45
iv Concealed wiring ndash group factor and
v Concealed wiring using ducts ndash surrounding temperature factor
Use of Minimum Cross Sectional Area Rating of Wiring ConductorsThe following are the minimum cross sectional areas of conductors based on their applications-
Use of Protection Conductor Minimum Cross Sectional Area Rating
In Comparison with Phase Conductor Cross Sectional Area
The following table shows the protection conductor minimum cross sectional area in comparison
with the phase conductor cross sectional area
Functions and Colour Identification of Non Flexible Cables
The following table shows the functions and colour identification of non flexible cables
11 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
33 Use of Minimum Cross Sectional Area Rating of Wiring Conductors
The following are the minimum cross sectional areas of conductors based on their applications-
34 Use of Protection Conductor Minimum Cross Sectional Area Rating
In Comparison with Phase Conductor Cross Sectional Area
The following table shows the protection conductor minimum cross sectional area in comparison
with the phase conductor cross sectional area
Use of Minimum Cross Sectional Area Rating of Wiring Conductors
The following are the minimum cross sectional areas of conductors based on their applications-
Use of Protection Conductor Minimum Cross Sectional Area Rating
In Comparison with Phase Conductor Cross Sectional Area
The following table shows the protection conductor minimum cross sectional area in comparison
with the phase conductor cross sectional area
Functions and Colour Identification of Non Flexible CablesThe following table shows the functions and colour identification of non flexible cables
12 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Flexible Cables
i Flexible cables of cross sectional area less than 40 mm2 are used in installations for electrical
accessories such as ceiling roses lamp fixtures or attachments socket plugs for mobile
appliances etc
ii Flexible cables shall not be used for permanent wiring
iii Flexible cables for the permanent use of electrical appliances should not exceed 3 meters in
length
37 Functions and Colour Identification of Flexible Cables
Conductor Insulation and Types of WiringVarious material and insulation layers are used for conductor protection Cable selection in
accordance to insulation layers must be done correctly for the type of the wiring installation as
shown in the table below
Functions and Colour Identification of Non Flexible CablesThe following table shows the functions and colour identification of non flexible cables
3 SELECTION OF WIRING ACCESSORIES
i All wiring accessories to be used have to be of those approved by the Energy Commission and
labeled with labels issued by SIRIM For all wiring using UPVC conduits -
13 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
a) Switches socket outlets 3 pin plugs ceiling roses connectors sockets ndash construction material shall
be of polycarbonate type
iii For all wiring using metal conduits - Switches socket outlets and connectors ndash construction
material shall be of metal clad type and All accessories shall be effectively earthed
iv Switch fuse used in single phase installations shall have the fuse permanently connected and not
move with the fuse
v Fuse switch used in 3 phase domestic installations also has fuse and switch The fuse connector is
installed together to allow the fuse to move simultaneously with the switch
vi Lamp
a) Fluorescent lamps using magnetic ballasts (watt loss not exceeding 6 watts) shall be
equipped with dry paper type capacitor
b) Fluorescent lamps using electronic ballasts or high frequency electronic ballasts do not
need capacitors
c) Outdoor domestic lamp installations shall use weather proof and water proof lamps
d) Submerged light installations (example in swimming pools fountains etc) shall have water
proof lamps with a voltage not exceeding 12 Volt AC
vii Electric water heaters is divided into 2 types namely
1 instantaneous water heaters and
2 stored water heaters (storage tank type)
a) Instantaneous water heaters shall be equipped with a 2 pole control switch and its own
residual current device
b) Storage water heaters (storage tank type) shall be installed with an
Water heaters exceeding 3kW shall be permanently connected to a 20A30A rated circuit
breakerfuse with an isolator switch and residual current device
viii Electric cookers exceeding 3kW shall have its own circuit connected permanently to a 30A rated
circuit breaker or fuse with an isolator switch and cooker control unit incorporated with a 13A socket
outlet Two or more cooker appliances may be installed in the same room within a distance of 2
meters
ix Electric motors (fence gate air conditioners fountains swimming pools fish ponds water
pumps) exceeding 373W but not exceeding 2238W shall be connected permanently to a 20A30A
rated circuit breakerfuse together with an isolator motor starter and 15A socket outlet
14 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
The motor starter shall be of Direct-On-Line type with the appliance together with the contactor
overload relay and on-off control The circuit breakerfuse which controls the motor circuit shall be
capable of withstanding the starting current of the motor
x Electric bells ndash the circuit shall have a push button switch and a ACDC transformer
xi Ceiling fans shall conform to clause 21101 of the MS 12192002 standard with regards to test on
the suspension system of ceiling fans
EARTHING OF ELECTRICAL INSTALLATIONS51 Earthing
Earthing is a connection system between the metallic parts of an electrical wiring system and the
general mass of the earth This will provide an easy path with a low impedence or resistance to earth to
enable the protection system to operate effectively It will thus ensure safety to human
beingsconsumers from the dangers of electric shocks if earth leakage currents are present In general
an electrical installation is earthed because of -
i Safety reasons
ii Protection system requirements
iii Need to limit over voltages
iv Need to provide a path for electrical discharge
v Legal requirements
52 Classification of Earthing
Generally earthing can be divided into 2 parts namely -
i System Earthing
a To isolate the system under fault conditions
b To limit the potential difference between conductors which are not insulated in an area
c To limit the occurrence of over voltages under various conditions
ii Equipment Earthing
Equipment earthing is undertaken to protect human beingsconsumers If a live source comes into
contact with the equipment body electrical energy will flow to the earth without flowing through the
human being consumerrsquos body This is because of the fact that the human body has a greater
resistance compared with the resistance to earth
53 Types and Functions of Earthing Accessories
Earthing accessories are as follows -
i Earthing Electrode
Copper jacketed steel core rods are used as electrodes for domestic wiring
ii Equipotential Bonding
15 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
This is the conductor which is connected between the consumer earthing point and the exposed
metallic part The minimum cable size for this purpose is 10 mm2
iii Protection Conductor
This is the conductor which connects the consumer earthing point with other parts of the installation
which needs earthing Its size is as follows-
a) Same size as the phase cable up to a size of 16mm2
b) 16 mm2 if the phase cable size is between 16 mm2 and 35 mm2
c) Half the size of the phase cable if the size of the phase cable exceeds 35 mm2
54 Earthing Arrangements Using a TT System
i The first alphabet indicates the earthing arrangements from the supply side
ii The second alphabet indicates the earthing arrangement in the consumerrsquos installation
T ndash first Indicates that the supply system has its own earthing arrangements
T ndash second Indicates that all metallic frames of the electrical appliances etc are connected directly to
earth
Parts that are Required to be Earthed
i All metallic structures in the wiring system (non current carrying) such as metallic covers conduits
ducts the armour of catenary wires etc
ii A secondary winding point in a transformer and
iii Frame of metal roof truss
56 Parts that are not Required to be Earthed
i Short isolated metallic parts for mechanical protection of cables which have non metallic sheaths
other than conduits which are connected at entry points between the building and conduits which
protect discharge lamp cables
ii Cable clips for installing cables
iii Metallic covers for lamps
16 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
iv Small metallic parts such as screws and name plates which are isolated by means of insulation
v Metallic lamp parts for filament lamps in water proof floors
57 Termination to Earth
The termination to earth is done as shown in Figure 72
Earth Electrode Resistance
The maximum permitted earth electrode resistance for different types of installations is as shown in
the Table below
Earth electrode for installations protected by RCDs of sensitivity 100mA 10 Ω
Lightning arrestor earth electrode 10 Ω
Legal Requirements
i Sub regulation 12(1) and 12(2) of the Electricity Regulations 1994 state that any electrical wiring in
an installation shall be under the immediate supervision of a Wireman with Single Phase Restriction or
Three Phase Restriction Upon completion the Wireman shall certify a Supervision and Completion
Certificate
ii Sub regulation 13(1) and 13 (2) of the Electricity Regulations 1994 state that the installation shall
be tested by a Wireman with Single Phase Restriction or a Wireman with Three Phase Restriction
authorized to test any installation and who shall certify a Test Certificate for the installation
iii Sub regulation 14(1) of the Electricity Regulations 1994 states that the Supervision and
Completion Certificate and the Test Certificate as in regulations 12 and 13 shall be in Forms G and H
respectively as prescribed in the First Schedule
17 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
4 SAFETY REQUIREMENTS FOR ELECTRICAL WIRING WORKS IN RESIDENTIAL BUILDINGS
61 Safety Requirements
Safety requirements for electrical wiring works have to be followed to eliminate any accidents which
can result in physical damage or loss of life or property Failure to meet the safety regulations may
result in workers consumers or the public being inflicted with electrical shocks
In addition to this safety steps will also encourage workers or electricity consumers who are
disciplined and who always give importance to safety
62 Safety Steps
Safety requirements have to be followed whenever electrical works are undertaken in a residential
building
i Personal Safety
a Use suitable personal protection equipment as needed such as safety shoes gloves safety helmet
etc when at the work place
b Use safety clothing suitable for the work to be undertaken
c Do not wear jewellery or decorative items such as rings watches chains etc while carrying out
electrical works
ii Safety at the Work Place
a Acquire knowledge about the dangers of electrical works that is to be undertaken and how to deal
with those dangers
b Always adhere to the safety regulations which have been set for the work place
c Ensure that the electricity supply is switched off before carrying out the works
d Acquire the needed knowledge and practice a cautious and calm attitude while working ensure
cleanliness in and around fellow workers
e While working at elevated places the worker should always use suitable equipment such as wooden
or aluminium ladders iron scaffoldings or platforms safety belts or other equipment needed to ensure
that the work can be undertaken safely
f Use electrical equipment which is operational and safe to be used and ensure that the supply for it is
being supplied through a residual current device (RCD) with a sensitivity of 30 mA
g Ensure that exposed temporary supply electrical cables have mechanical protection
h If inflammable or corrosive material is present necessary safety steps have to be undertaken as
required by the relevant safety regulations
63 Dangers of Electrical Shocks
i Electrical Shock
Electrical shocks can occur due to direct or indirect contact
a Direct Contact
18 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Direct contact occurs when the worker or consumer receives an electrical shock on touching directly a
live conductor or cable
b Indirect Contact
Here the electric shock occurs due to contact with a part which is connected to the electrical
installation and not to a direct contact with a live cable or conductor possibly due to damages in the
appliance or insulation resulting in leakages of current
Why Electric Shocks Occura Unsafe Work Method or Action Undertaking Electrical Work Without Disconnecting the
Supply
Maintenance or circuit testing work done without disconnecting the supply will have a high possibility
of electrical shocks occurring
bull Not Following Safe Work Procedures
To eliminate the occurrence of electrical shocks each worker has to always follow safe work
procedures which are set by regulations and standards
b Defects in the Electrical System
i Leakage Current
Leakage currents or earth leakage currents can result in the metallic frames becoming live and
energised This can give rise to the danger of electrical shock to the worker consumer or the public if
they hold or come into contact with the metallic frame
ii Exposed Conductor or Disconnected Cable
Exposed conductors or cables which are broken and are alive (energised) can result in electrical shock
when touched The supply source must be immediately isolated or switched off and a report must be
made to the responsible entity
64 First Aid and Basic Pulmonary Resuscitation
i First Aid
First aid is the initial assistance given to a person who has met with an accident is sick or is injured to
prevent the condition of the victim from becoming more serious while awaiting the arrival of the
paramedics (ambulance) or before being brought to the hospital
i Pulmonary Resuscitation
Pulmonary resuscitation has to be undertaken to assist the victim who has breathing difficulties as a
result of being drowned receiving an electrical shock etc Pulmonary resuscitation has to be carried
out in accordance to the correct method as stated in the first aid manuals issued by accredited first aid
bodies
ii First Aid Box
19 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
A first aid box has to be provided by the building owner construction site supervisor or brought
personally by the worker under the supervision of the responsible person
65 Training Programme
The management shall conduct periodic training programmes for the workers with regards to work
safety on aspects including the following -
i Dangers of electrical work being undertaken and how to control those dangers
ii The safety regulations set for the work place and
iii First aid procedures
66 Fire Prevention
Fire Extinguisher A suitable functioning fire extinguisher to control fires has to be made available at
the work place at all times
67 Competent Person
The Electricity Regulations 1994 require that all electrical work has to be undertaken by or under the
direct supervision of a competent person registered with the Energy Commission Besides that the
electrical contractor undertaking the electrical work has also to be registered with the Energy
Commission The installation owner thus has to ensure that the appointed electrical contractor is
registered with the Energy Commission and that the registration is still valid
INSTALLATION CIRCUITS AND SYSTEMS1 Block diagrams
These show using squares rectangles etc the sequence of a system without too much technical detail
eg Figures 1517 and 1526
2 Layout diagrams
These are very similar to block diagrams but they indicate more technical detail and tend to show
items in their correct geographical location (eg Figures 1518 and 1519)
3 Circuitschematic
These show how a circuit functions and takes no account of exact locations of terminals or equipment
(eg Figures 1528 1529 1532 1534 etc)
4 Wiring diagram
These indicate how a circuit or system is physically wired (eg Figures 152 154 156 etc)
Most induction motors are started directly on line but when very large motors are started that way
they cause a disturbance of voltage on the supply lines due to large starting current surges To limit the
starting current surge large induction motors are started at reduced voltage and then have full supply
voltage reconnected when they run up to near rotated speed Two methods are used for reduction of
starting voltage are star delta starting and auto transformer stating
20 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Working Principal of Star-Delta Starter
This is the reduced voltage starting method Voltage reduction during star-delta starting is achieved by
physically reconfiguring the motor windings as illustrated in the figure below During starting the
motor windings are connected in star configuration and this reduces the voltage across each winding 3
This also reduces the torque by a factor of three After a period of time the winding are reconfigured as
delta and the motor runs normally
StarDelta starters are probably the most common reduced voltage starters They are used in
an attempt to reduce the start current applied to the motor during start as a means of reducing the
disturbances and interference on the electrical supply
Traditionally in many supply regions there has been a requirement to fit a reduced voltage
starter on all motors greater than 5HP (4KW) The StarDelta (or WyeDelta) starter is one of the
lowest cost electromechanical reduced voltage starters that can be applied
The StarDelta starter is manufactured from three contactors a timer and a thermal overload
The contactors are smaller than the single contactor used in a Direct on Line starter as they are
controlling winding currents only The currents through the winding are 1root 3 (58) of the
current in the line
There are two contactors that are close during run often referred to as the main contractor and
the delta contactor These are AC3 rated at 58 of the current rating of the motor The third
contactor is the star contactor and that only carries star current while the motor is connected in star
The current in star is one third of the current in delta so this contactor can be AC3 rated at one
third (33) of the motor rating
Star-delta Starter Consists following units
1) Contactors (Main star and delta contactors) 3 Norsquos (For Open State Starter) or 4 Norsquos (Close
Transient Starter)
2) Time relay (pull-in delayed) 1 No
3) Three-pole thermal over current release 1No
4) Fuse elements or automatic cut-outs for the main circuit 3 Nos
5) Fuse element or automatic cut-out for the control circuit 1No
Power Circuit of Star Delta Starter
1 The main circuit breaker serves as the main power supply switch that supplies electricity to the
power circuit
2 The main contactor connects the reference source voltage R Y B to the primary terminal of the
motor U1 V1 W1
21 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
3 In operation the Main Contactor (KM3) and the Star Contactor (KM1) are closed initially and
then after a period of time the star contactor is opened and then the delta contactor (KM2) is
closed The control of the contactors is by the timer (K1T) built into the starter The Star and Delta
are electrically interlocked and preferably mechanically interlocked as well In effect there are
four states
4 The star contactor serves to initially short the secondary terminal of the motor U2 V2 W2 for the
start sequence during the initial run of the motor from standstill This provides one third of DOL
current to the motor thus reducing the high inrush current inherent with large capacity motors at
startup
5 Controlling the interchanging star connection and delta connection of an AC induction motor is
achieved by means of a star delta or wye delta control circuit The control circuit consists of push
button switches auxiliary contacts and a timer
Control Circuit of Star-Delta Starter (Open Transition)
1 The ON push button starts the circuit by initially energizing Star Contactor Coil (KM1) of star
circuit and Timer Coil (KT) circuit
2 When Star Contactor Coil (KM1) energized Star Main and Auxiliary contactor change its
position from NO to NC
3 When Star Auxiliary Contactor (1)( which is placed on Main Contactor coil circuit )became
NO to NC itrsquos complete The Circuit of Main contactor Coil (KM3) so Main Contactor Coil
energized and Main Contactorrsquos Main and Auxiliary Contactor Change its Position from NO
To NC This sequence happens in a friction of time
4 After pushing the ON push button switch the auxiliary contact of the main contactor coil (2)
which is connected in parallel across the ON push button will become NO to NC thereby
providing a latch to hold the main contactor coil activated which eventually maintains the
control circuit active even after releasing the ON push button switch
5 When Star Main Contactor (KM1) close its connect Motor connects on STAR and itrsquos
connected in STAR until Time Delay Auxiliary contact KT (3) become NC to NO
6 Once the time delay is reached its specified Time the timerrsquos auxiliary contacts (KT)(3) in
Star Coil circuit will change its position from NC to NO and at the Same Time Auxiliary
contactor (KT) in Delta Coil Circuit(4) change its Position from NO To NC so Delta coil
energized and Delta Main Contactor becomes NO To NC Now Motor terminal connection
change from star to delta connection
7 A normally close auxiliary contact from both star and delta contactors (5amp6)are also placed
opposite of both star and delta contactor coils these interlock contacts serves as safety
switches to prevent simultaneous activation of both star and delta contactor coils so that one
22 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
cannot be activated without the other deactivated first Thus the delta contactor coil cannot be
active when the star contactor coil is active and similarly the star contactor coil cannot also
be active while the delta contactor coil is active
8 The control circuit above also provides two interrupting contacts to shutdown the motor
The OFF push button switch break the control circuit and the motor when necessary The
thermal overload contact is a protective device which automatically opens the STOP Control
circuit in case when motor overload current is detected by the thermal overload relay this is to
prevent burning of the motor in case of excessive load beyond the rated capacity of the motor
is detected by the thermal overload relay
9 At some point during starting it is necessary to change from a star connected winding to a
delta connected winding Power and control circuits can be arranged to this in one of two
ways ndash open transition or closed transition
What is Open or Closed Transition Starting
(1) Open Transition Starters
Discuss mention above is called open transition switching because there is an open state between
the star state and the delta state
In open transition the power is disconnected from the motor while the winding are reconfigured via
external switching
When a motor is driven by the supply either at full speed or at part speed there is a rotating
magnetic field in the stator This field is rotating at line frequency The flux from the stator field
induces a current in the rotor and this in turn results in a rotor magnetic field
When the motor is disconnected from the supply (open transition) there is a spinning rotor within
the stator and the rotor has a magnetic field Due to the low impedance of the rotor circuit the time
constant is quite long and the action of the spinning rotor field within the stator is that of a
generator which generates voltage at a frequency determined by the speed of the rotor When the
motor is reconnected to the supply it is reclosing onto an unsynchronized generator and this result
in a very high current and torque transient The magnitude of the transient is dependent on the
phase relationship between the generated voltage and the line voltage at the point of closure can
be much higher than DOL current and torque and can result in electrical and mechanical damage
Open transition starting is the easiest to implement in terms or cost and circuitry and if the timing
of the changeover is good this method can work well In practice though it is difficult to set the
necessary timing to operate correctly and disconnectionreconnection of the supply can cause
significant voltagecurrent transients
In Open transition there are Four states
23 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 OFF State All Contactors are open
2 Star State The Main [KM3] and the Star [KM1] contactors are closed and the delta [KM2]
contactor is open The motor is connected in star and will produce one third of DOL torque at one
third of DOL current
3 Open State This type of operation is called open transition switching because there is an
open state between the star state and the delta state The Main contractor is closed and the Delta
and Star contactors are open There is voltage on one end of the motor windings but the other end
is open so no current can flow The motor has a spinning rotor and behaves like a generator
4 Delta State The Main and the Delta contactors are closed The Star contactor is open The
motor is connected to full line voltage and full power and torque are available
(2) Closed Transition StarDelta Starter
There is a technique to reduce the magnitude of the switching transients This requires the use of a
fourth contactor and a set of three resistors The resistors must be sized such that considerable
current is able to flow in the motor windings while they are in circuit
The auxiliary contactor and resistors are connected across the delta contactor In operation just
before the star contactor opens the auxiliary contactor closes resulting in current flow via the
resistors into the star connection Once the star contactor opens current is able to flow round
through the motor windings to the supply via the resistors These resistors are then shorted by the
delta contactor If the resistance of the resistors is too high they will not swamp the voltage
generated by the motor and will serve no purpose
In closed transition the power is maintained to the motor at all time This is achieved by
introducing resistors to take up the current flow during the winding changeover A fourth
contractor is required to place the resistor in circuit before opening the star contactor and then
removing the resistors once the delta contactor is closed These resistors need to be sized to carry
the motor current In addition to requiring more switching devices the control circuit is more
complicated due to the need to carry out resistor switching
In Close transition there are Four states
1 OFF State All Contactors are open
2 Star State The Main [KM3] and the Star [KM1] contactors are closed and the delta [KM2]
contactor is open The motor is connected in star and will produce one third of DOL torque at one
third of DOL current
Star Transition State The motor is connected in star and the resistors are connected across the
delta contactor via the aux [KM4] contactor
24 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Closed Transition State The Main [KM3] contactor is closed and the Delta [KM2] and Star
[KM1] contactors are open Current flows through the motor windings and the transition resistors
via KM4
Delta State The Main and the Delta contactors are closed The transition resistors are shorted out
The Star contactor is open The motor is connected to full line voltage and full power and torque
are available
Effect of Transient in Starter (Open Transient starter)
It is Important the pause between star contactor switch off and Delta contactor switch is on correct
This is because Star contactor must be reliably disconnected before Delta contactor is activated It
is also important that the switch over pause is not too long
For 415v Star Connection voltage is effectively reduced to 58 or 240v The equivalent of 33
that is obtained with Direct Online (DOL) starting
If Star connection has sufficient torque to run up to 75 or 80 of full load speed then the motor
can be connected in Delta mode
When connected to Delta configuration the phase voltage increases by a ratio of V3 or 173 The
phase currents increase by the same ratio The line current increases three times its value in star
connection
During transition period of switchover the motor must be free running with little deceleration
While this is happening ldquoCoastingrdquo it may generate a voltage of its own and on connection to the
supply this voltage can randomly add to or subtract from the applied line voltage This is known as
transient current Only lasting a few milliseconds it causes voltage surges and spikes Known as
a changeover transient
Size of each part of Star-Delta starter
(1) Size of Over Load Relay
For a star-delta starter there is a possibility to place the overload protection in two positions in the
line or in the windings
Overload Relay in Line
In the line is the same as just putting the overload before the motor as with a DOL starter
The rating of Overload (In Line) = FLC of Motor
Disadvantage If the overload is set to FLC then it is not protecting the motor while it is in delta
(setting is x1732 too high)
Overload Relay in Winding
25 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
In the windings means that the overload is placed after the point where the wiring to the contactors
are split into main and delta The overload then always measures the current inside the windings
The setting of Overload Relay (In Winding) =058 X FLC (line current)
Disadvantage We must use separate short circuit and overload protections
(2) Size of Main and Delta Contractor
1 There are two contactors that are close during run often referred to as the main contractor and
the delta contactor These are AC3 rated at 58 of the current rating of the motor
Size of Main Contactor= IFL x 058
(3) Size of Star Contractor
The third contactor is the star contactor and that only carries star current while the motor is
connected in star The current in star is 1 radic3= (58) of the current in delta so this contactor can
be AC3 rated at one third (33) of the motor rating
Size of Star Contactor= IFL x 033
Motor Starting Characteristics of Star-Delta Starter
Available starting current 33 Full Load Current
Peak starting current 13 to 26 Full Load Current
Peak starting torque 33 Full Load Torque
Advantages of Star-Delta starter
The operation of the star-delta method is simple and rugged
It is relatively cheap compared to other reduced voltage methods
Good TorqueCurrent Performance
It draws 2 times starting current of the full load ampere of the motor connected
Disadvantages of Star-Delta starter
Low Starting Torque (Torque = (Square of Voltage) is also reduce)
Break In Supply ndash Possible Transients
Six Terminal Motor Required (Delta Connected)
It requires 2 set of cables from starter to motor
It provides only 33 starting torque and if the load connected to the subject motor requires higher
starting torque at the time of starting than very heavy transients and stresses are produced while
changing from star to delta connections and because of these transients and stresses many
electrical and mechanical break-down occurs
26 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
In this method of starting initially motor is connected in star and then after change over the motor
is connected in delta The delta of motor is formed in starter and not on motor terminals
High transmission and current peaks When starting up pumps and fans for example the load
torque is low at the beginning of the start and increases with the square of the speed When
reaching approx 80-85 of the motor rated speed the load torque is equal to the motor torque and
the acceleration ceases To reach the rated speed a switch over to delta position is necessary and
this will very often result in high transmission and current peaks In some cases the current peak
can reach a value that is even bigger than for a DOL start
Applications with a load torque higher than 50 of the motor rated torque will not be able to start
using the start-delta starter
Low Starting Torque The star-delta (wye-delta) starting method controls whether the lead
connections from the motor are configured in a star or delta electrical connection The initial
connection should be in the star pattern that results in a reduction of the line voltage by a factor of
1radic3 (577) to the motor and the current is reduced to 13 of the current at full voltage but the
starting torque is also reduced 13 to 15 of the DOL starting torque
The transition from star to delta transition usually occurs once nominal speed is reached but is
sometimes performed as low as 50 of nominal speed which make transient Sparks
Features of star-delta starting
1 For low- to high-power three-phase motors
2 Reduced starting current
3 Six connection cables
4 Reduced starting torque
5 Current peak on changeover from star to delta
6 Mechanical load on changeover from star to delta
Application of Star-Delta Starter
The star-delta method is usually only applied to low to medium voltage and light starting
Torque motors
The received starting current is about 30 of the starting current during direct on line start and the
starting torque is reduced to about 25 of the torque available at a DOL start This starting
method only works when the application is light loaded during the start If the motor is too heavily
27 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
loaded there will not be enough torque to accelerate the motor up to speed before switching over
to the delta position
LESSON 1 WIRING SYSTEM OF SINGLE PHASE DISTRIBUTION BOARD
Introduction
28 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
29 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
30 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
31 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 2 WIRING SYSTEM OF SINGLE PHASE LIGHTING CIRCUIT Introduction
Objectives
1 Identify component and the specification
2 Wire component according to the schematic diagram
3 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Wiring bay Perforated metal 180 cm x 180 cm 1
2 Cut out fuse 63 A 240 V 1
3 Neutral link 1
4 Single pole one way switch cw
switch box
5A 240Vac 4
5 single pole two way switch cw
switch box
5A 240Vac 2
6 RCCB In = 40 A Tripping current
100mA240 Vac 50 Hz
1
7 Main switch 32 A 240V 1
8 kWatthour meter 40 A 240 Vac 1
9 Single pole MCB 6A 240 Vac 1
10 Self tapping Wood screw As required
11 DIN rail 35 mm width As required
32 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
12 PVC trunking 50 mm x 50 mm As required
13 Terminal blocks 5 A As required
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
1 One way switch to control one lamp
2 One way switch to control two lamps
3 Two of two way switch to control one lamp
4 Two of single pole two way switch and one of an intermediate switch to control one
lamp
5 One unit of ceiling fan and fan regulator to be controlled by one way switch
4 Test the functionality of completed project
LESSON 3ndash WIRING SYSTEM OF SINGLE PHASE POWER CIRCUIT Introduction
33 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
34 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify types of component and its specification
2 Wire component according to the schematic diagram given
3 Test the functionality of the circuit dead circuit test life circuit test
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board Perforated Metal 1
2 kWh meter 240 V 40 A 1
3 Socket outlet 13A 240Vac 4
4 RCCB 40A Trip Amps
30mA240 Vac
1
5 3 pin socket 240Vac 13A 4
6 Single pole MCB 20A 240 V 2
7 DOL starter 1 kW 240Vac 2
8 1 phase induction motor 2Hp 240 Vac 1
9 Cooker control unit 4kW 240Vac 1
10 Water heater point 4kW 240 Vac 1
11 DIN rail 35 mm As required
12 PVC casing 20mm As required
13 Flexible wires 05 mm As required
14 Terminal block 10 A As required
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Wire two unit of 13 A socket outlet in radial circuit
3 Wire four units of 13 A socket outlet in ring circuit
4 Wire one unit DOL starter for air-conditioner point
5 Wire one unit of cooker control unit point
6 Wire one unit of water heater point
7 Test the functionality of each component by using mmeter or power supply whichever
applicable
8 Wire component according to circuit diagram
9 Test the functionality of completed project dead circuit test life circuit test
Note
35 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Ensure that the correct rating of protection device and size of wire used
LESSON 4ndash CONDUIT BENDING AND TRUNKING FABRICATION TECHNIQUE
Common fitting used in an industrial wiring
Cutting and threading the condute
36 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
37 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
38 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify conduit fitting and the specification
2 Measure and Cut steel conduit according to specified dimension
3 Bend and fabricate conduit at 45 90 according to layout diagram
4 Wire component according to the schematic diagram
5 Test the functionality of the circuit
39 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Conduit Bender Oslash 19 mm ( frac34 ldquo) 1
2 Measuring Tape 3 metre 1
3 Hacksaw frame and blade 30cm 1
4 Conduit cutter 1
5 Pipe Vise 1
6 Pipe Wrench 1
7 Ratchet Dies 20 mm 1
8 Metal trunking 50 mm x 50 mm 1
9 GI conduit 20mm 1
10 End box 20 mm 1
11 Flexible wires 05 mm As required
12 Connectors 5 A As required
13 Single core PVC ins Cable 25 mm 2 As required
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Wire two unit of 13 A socket outlet in radial circuit
3 Wire four unit of 13 A socket outlet in ring circuit
4 Wire one unit DOL starter for air-conditioner point
5 Wire one unit of cooker control unit point
6 Wire one unit of water heater point
7 Test the functionality of each component by using multimeter or power supply whichever
applicable
8 Wire component according to circuit diagram
9 Test the functionality of completed project
Note
Ensure that the rating of protection device and size of wire
K prior to 31 March
2004 (BS 7671)
(formerly)
bare conductor
sleeved at terminations (formerly)
40 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 5 ndashWIRING SYSTEM OF 1 Oslash LIGHTING AND POWER CIRCUIT
POWER CIRCUITSa Radial circuits
Radial circuits are arranged in the same way as item 1 above in lighting layouts in that each socket
outlet is supplied via the previous one
Points to note
1 The number of socket outlets complying with BS 1363 is unlimited for a floor area of up to 50m 2 if
the circuit protection is a 30 A or 32 A cartridge fuse or circuit breaker the cable being 4 mm PVC
copper or 25 mm2 mineral insulated (mi)
2 The number of socket outlets is unlimited for a floor area up to 20 m 2 with any type of circuit
protection of 20 A using 25 mm2 PVC copper cable or 15 mm2 mi
3 The total number of fused spurs is unlimited
b ring final circuits
These circuits are the same as radial circuits except that the final socket outlet is wired back to the
supply position In effect any outlet is supplied from two directions (Fig 152)
Points to note
1 Every twin-socket outlet counts as two single-socket outlets
2 The number of non-fused spurs must not exceed the total number of points on the ring Fig 158
shows seven points on the ring and five spurs
3 The fuse rating of a fused spur box must not exceed 13 A and the current rating of all points supplied
by the fused spur must not exceed 13 A
4 Non-fused spurs must supply no more than one single or one double socket on the ring Fig 158
shows seven points on the ring and five spurs rating of all points supplied by the fused spur must not
exceed 13 A or one stationary appliance
CapacityMain conductor size
copper (mm2)
Earth conductor
size (mm2)
Circuit breaker
capacity (A)
Up to 600 W 15 15 6
600ndash1200 W 1525 15 10
1200ndash1800 W 254 25 16
41 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Ring circuit
(floor area 100 m2)25 15 3032
A2 radial circuit
(floor area 75 m2)40 25 3032
A3 radial circuit
(floor area 50 m2)25 15 20
Air conditioner (15 tonne) 60 60 3032
Cooker 60 60 3032
Water heater 40 40 20
Objectives
1 Identify component and the specification
2 Wire component according to the schematic diagram
3 Test the functionality of the circuit
42 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board Perforated 1
2 Cut out fuse and neutral link 60A 240V 1each
3 kWh meter 240V 40A 1
4 Switched Socket outlet 13A 240Vac 4
5 Single pole two way switch cw switch
box
5A 240Vac 2
6 RCCB ELCB 63 A Tripping current 100mA
415 Vac
1
7 3 pin plug 240Vac 13A 4
8 Single pole MCB 20 A 2
9 Single pole MCB 6A 1
10 Single pole MCB 20A 2
11 DOL starter 240Vac 2
12 1 phase induction motor 2hp 240 Vac 1
13 Self tapping Wood screw As required
14 DIN rail Stainless steel allum35 mm As required
15 PVC pipe 20mm dia As required
16 End box 20 mm dia 4
17 Flexible wires 05 mm 2 As required
18 Connectors 5 A As required
Procedures
43 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
4 Test the functionality of completed project
LESSON 6 ndash WIRING SYSTEM OF 3 Oslash DISTRIBUTION BOARD
Introduction
44 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
45 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
46 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
47 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
48 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify each component and the specification
2 Wire component according to the schematic diagram given
3 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting Board 450 x 600 mm Perforated metal 1
2 5 pin round socket and plug 415V ac 32A 1
3 Cut out fuse 60 A 3
4 Neutral link 1
5 kWatt hour meter 415V 60A 1
6 ELCB RCCB 3P+N In=63A415 Vac I trip= 300mA 1
7 ELCB RCCB 3P+N In=63A415 Vac I trip= 30mA 1
8 Single pole MCB 6A 240 V 3
9 Single pole MCB 20A 240 V 3
10 DOL starter 20 A 240Vac 2
11 Socket outlet 15 A 240 Vac 1
12 Switched Socket outlet 13 A 240 Vac 3
13 Led indicating light 5A 240 Vac 3
14 Single pole 4 gang 1 way switch 5A 240 Vac 2
15 Single pole 2 way switch 5A 240 Vac 2
16 1 phase induction motor 1 kW 240Vac 1
17 Metal trunking 30 mm x30 mm As required
18 Self tapping Wood screw 4 mm x 20 mm As required
19 DIN rail 25 mm x 1mm
20 GI steel rigid conduit 20mm As required
21 Flexible conduit 20mm As required
22 End box 20 mm 4
23 Flexible wires 05 mm 2 As required
24 Single core PVC insulated wire 15 mm 2 As required
25 Single core PVC insulated wires 25 mm 2 As required
26 Terminal block 10 A As required
Procedures
49 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify each components and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
4 Test the functionality of completed project
1 dead circuit test
2 life circuit
Note Proper earthing should be made
50 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 7 ndash WIRING SYSTEM OF THREE PHASE LIGHTING AND POWER CIRCUIT
51 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
52 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify component and the specification
2 Wire component according to the schematic diagram
3 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting bay Board Perforated metal 180 cm x 180 cm 1
2 k Watt hour meter 415V 60A 1
3 MCCB 415V 60A
4 ELCB RCCB In=60A415 Vac I trip=30mA 1
5 5 pin round Socket and
plug
415Vac 32A 4
6 Single pole MCB 6A 1
7 Triple pole MCB 20A 2
8 Triple pole Main switch 60A 1
9 DOL starter 240Vac 2
10 3 phase induction motor 2hp 415 Vac 1
11 1 phase induction motor 1
12 Metal trunking 30 mm x30 mm As required
13 Self tapping Wood screw 4 mm x 20 mm As required
14 DIN rail 25 mm x 1mm
15 GI steel rigid conduit 20mm As required
16 Flexible conduit 20mm As required
17 End box 20 mm 4
18 Flexible wires 05 mm As required
19 Connectors 10 A As required
Procedures
1 Identify each components and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
4 Test the functionality of completed project
1 dead circuit 2 life circuit test
5 Record the current drawn by the load as connected in star and delta
Note Proper earthing should be made
53 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 8 INSPECTION AND TESTING OF ELECTRICAL INSTALLATION
On completion of a wiring installation a number of tests on the installation have to be conducted to
ascertain that the wiring circuits and connected appliances are safe for use Prior to carrying out the
tests an inspection has to be done The results of the inspectionsupervision and test have to be
presented in Form G (as in Appendix IV) and Form H (as in Appendix V)
To have the test certification as in Form H the following tests shall be conducted
i Continuity Test
ii Insulation Resistance Test
iii Polarity Test
iv Earth Electrode Resistance test and
v Residual Current Device Test
1 Continuity Test
There are 3 main types of continuity tests for the final circuits-
i Protection Conductor Continuity Test
ii Final Ring Circuit Conductor Continuity Test
iii Live and Neutral Conductor Continuity Test
a) Protection Conductor Continuity Test
bull To ascertain that all protection conductors are connected in the correct and effective manner
bull Test equipment ndash Multimeter (Ohm range) or Ohm meter
54 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
bull Test Method
1 1048766 Ensure that the main switch RCD and MCB are open circuited (switched off) and all loads
are disconnected
2 1048766 Connected the test leads as in the Figure 81 The meter reading shall be less than 1 Ω
55 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Final Ring Circuit Conductor Continuity Test
bull To ensure that all conductors around the ring circuit have continuity
bull Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
bull Test Method
1 1048766 Disconnect both the supply source live conductors from the MCB the neutral conductor
from the neutral terminals and the earth conductor from the earth terminal in the distribution
fuse box
2 1048766 Connect the test leads as in the Figure 82 (EE)
3 1048766 Repeat the procedure for (L-L) and (N-N)
4 1048766 The meter reading value shall be less than 1 ohm
56 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Live and Neutral Conductor Continuity Test
a To ensure that each conductor in the circuit has continuity
b Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
2 Test Method
1 1048766 Switch off the Main switch RCD and MCB
2 1048766 Disconnect all loads
3 1048766 Switch on all switches in the circuit
4 1048766 Disconnect the fusesfinal circuit breakers and close the circuit
5 1048766 Carry out the test as shown in Figure 83
6 1048766 The meter reading value shall be less than 1Ω
57 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
58 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
CONTINUITY TEST
Insulation Resistance Test
i Ensure that there is no leakage current between phase conductors phase and neutral conductors and
phase conductor and earth
ii Test the strength of the cable insulation
iii Test Equipment ndash Insulation Resistance Tester operating voltage is 250VDC or 500VDC
iv Test Method
1 1048766 Switch off main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
59 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
4 1048766 Carry out test as in the Table below
5 1048766 Meter reading value shall be less than 1 Megaohm
60 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
61 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Insulation resitance test
62 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
INSULATION RESISTANCE TEST BETWEEN CONDUCTORS AND OPPOSITE POLARITY
Polarity Testi Ensure that each fuse or single pole control and protection device is connected only in the phase
conductor
ii Intermediate contact of Edison screw lamp holder is connected to the phase conductor
iii Ensure that phase neutral and earth conductors at socket outlets are connected at the correct
terminals
iv Test Equipment ndash Multimeter (Ohm range) or Ohm meter
v Test Method
1 1048766 Switch off Main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in Figure 85
63 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
5 1048766 Test switches and single phase control devices at the phase conductors
6 1048766 Test socket outlet connection sources
7 1048766 Test Edison screw lamp holder connections
8 1048766 Meter reading value shall be less than 1 Ω
64 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Polarity test
65 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Earth Electrode Resistance Testi To test the earth electrode resistance
ii To ascertain the suitability of the location of the electrode
iii To ensure that the electrode is not buried within the resistance area of another electrode
iv Test equipment ndash Earth Resistance Tester
v Test method -
1 1048766 Terminal rsquoErsquo is connected to the electrode to be tested (green conductor)
2 1048766 Terminal lsquoPrsquo is connected to the potential spike (yellow conductor) at a distance of 10
meters from the earth electrode
3 1048766 Terminal lsquoCrsquo is connected to the current spike (red conductor) at a distance of 20 meters
from the earth electrode
Earth Electrode Resistance Measurement Method (Figure 86)
This test must be repeated at least three times to ensure that the reading is not affected by interacting
earthing regions
i Record the first reading (Z1) Example Z1 = 10 Ω
ii Move the voltage spike to a distance of 6 meters from the original position Record the second
reading (Z2 ) Example Z2 = 10 Ω
iii Move the voltage spike to a distance of 6 meters from the original position Record the third
reading (Z3) Example Z3 = 10 Ω
66 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Residual Current Device Testi Ensure that the residual current device (RCD) trips within the set time on the occurrence of current
leakage to earth
ii Test Equipment ndash RCD Tester RCCB Tester
iii Test Method 1
1 1048766 Use the Trip Test Button
2 1048766 Press the trip button found on the RCD to determine if it trips or otherwise This test would
not be able to determine the sensitivity of the RCD nor the time taken for it to trip
iv Test Method 2
i 1048766 Use a RCD Tester
ii This equipment is equipped with a 13A plug which can be connected to a 13A socket outlet
Select the RCD sensitivity to be the same as the sensitivity of the RCD to be tested to
determine if the RCD can trip The time to trip shall not exceed 40 mS
iii 1048766 Test method ndash
a) Position the selection switch in accordance with the sensitivity of the RCD used
Example 100 mA 01 A
b) Position the operations switch to lsquoNo Triprsquo (frac12 Rated mA = 50) connect the 3 pin plug to
the 13A socket outlet
67 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
c) Switch on the 13A socket outlet ndash ensure that the P-N and P-E lights light up
This shows that the polarity is correct (Note if both the lights as above do not light up the test cannot
be continued)
d) Press the test button ndash the reading shows less than 200 mS and simultaneously the lsquotestrsquo light lights
up and the P-N and P-E lights do not light up At that instant the RCD will not trip
e) Move the selection switch to 180o (+ve wave) ndash repeat steps (d) and (e) Move the operations
switch to lsquoTriprsquo (Rated mA = 100)
g) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200mS
h) Move the selection switch to 0o (-ve wave)
i) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
j) The above test is repeated until a near correct reading is obtained
k) Record the test results
l) Change the operations switch to lsquoFast Triprsquo and press the test button ndash RCD will trip within a
time not exceeding 40 millisecond
m) Repeat a number of times at 0o or 180o
On completion of a wiring installation a number of tests on the installation have to be conducted to
ascertain that the wiring circuits and connected appliances are safe for use Prior to carrying out the
tests an inspection has to be done the following tests shall be conducted
i Continuity Test
ii Insulation Resistance Test
iii Polarity Test
iv Earth Electrode Resistance test and
v Residual Current Device Test
821 Continuity Test
There are 3 main types of continuity tests for the final circuits-
i Protection Conductor Continuity Test
ii Final Ring Circuit Conductor Continuity Test
68 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
iii Live and Neutral Conductor Continuity Test
a) Protection Conductor Continuity Test
bull To ascertain that all protection conductors are connected in the correct and effective manner
bull Test equipment ndash Multimeter (Ohm range) or Ohm meter
bull Test Method
1 1048766 Ensure that the main switch RCD and MCB are open circuited (switched off) and all loads are
disconnected
2 1048766 Connected the test leads as in the Figure 81
3 1048766 The meter reading shall be less than 1 Ω
Final Ring Circuit Conductor Continuity Test
bull To ensure that all conductors around the ring circuit have continuity
bull Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
bull Test Method
1 1048766 Disconnect both the supply source live conductors from the MCB the neutral conductor
from the neutral terminals and the earth conductor from the earth terminal in the distribution
fuse box
2 1048766 Connect the test leads as in the Figure 82 (EE)
3 1048766 Repeat the procedure for (L-L) and (N-N)
4 1048766 The meter reading value shall be less than 1 ohm Figure 82 - Final Ring Circuit Conductor
Continuity Test Ohm Meter
Disconnect both the supply source cables from mcbfuse
Take readings at earth conductors of both sources and note resistance readings
Live and Neutral Conductor Continuity Test
1 To ensure that each conductor in the circuit has continuity
2 Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
3 Test Method
1 1048766 Switch off the Main switch RCD and MCB
2 1048766 Disconnect all loads
3 1048766 Switch on all switches in the circuit
4 1048766 Disconnect the fusesfinal circuit breakers and close the circuit
5 1048766 Carry out the test as shown in Figure 83
6 1048766 The meter reading value shall be less than 1 ohm Figure 83 - Live and Neutral
Conductor Continuity Test Ohm Meter
Insulation Resistance Test
69 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
i Ensure that there is no leakage current between phase conductors phase and neutral conductors and
phase conductor and earth
ii Test the strength of the cable insulation
iii Test Equipment ndash Insulation Resistance Tester Operating voltage is 250VDC or 500VDC
iv Test Method
1 1048766 Switch off main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in the Table below
5 1048766 Meter reading value shall be less than 1 Megaohm
Polarity Test
i Ensure that each fuse or single pole control and protection device is connected only in the phase
conductor
ii Intermediate contact of Edison screw lamp holder is connected to the phase conductor
iii Ensure that phase neutral and earth conductors at socket outlets are connected at the correct
terminals
iv Test Equipment ndash Multimeter (Ohm range) or Ohm meter
v Test Method
1 1048766 Switch off Main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in Figure 85
5 1048766 Test switches and single phase control devices at the phase conductors
6 1048766 Test socket outlet connection sources
7 1048766 Test Edison screw lamp holder connections
8 1048766 Meter reading value shall be less than 1 Ω
Earth Electrode Resistance Test
i To test the earth electrode resistance
70 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
ii To ascertain the suitability of the location of the electrode
iii To ensure that the electrode is not buried within the resistance area of another electrode
iv Test equipment ndash Earth Resistance Tester
v Test method -
1 1048766 Terminal rsquoErsquo is connected to the electrode to be tested (green conductor)
2 1048766 Terminal lsquoPrsquo is connected to the potential spike (yellow conductor) at a distance of 10
meters from the earth electrode
3 1048766 Terminal lsquoCrsquo is connected to the current spike (red conductor) at a distance of 20 meters
from the earth electrode E P C Electrode 10 meter 10 meter
Figure 86 ndash Earth Electrode Resistance Measurement Test Equipment
Earth Electrode Resistance Measurement Method (Figure 86)
This test must be repeated at least three times to ensure that the reading is not affected by interacting
earthing regions
i Record the first reading (Z1) Example Z1 = 10 Ω
ii Move the voltage spike to a distance of 6 meters from the original position Record the second
reading (Z2) Example Z2 = 10 Ω
iii Move the voltage spike to a distance of 6 meters from the original position Record the third
reading (Z3)
Example Z3 = 10 Ω
Residual Current Device Test
71 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
i Ensure that the residual current device (RCD) trips within the set time on the occurrence of current
leakage to earth
ii Test Equipment ndash RCD Tester RCCB Tester
iii Test Method 1
1 1048766 Use the Trip Test Button
2 1048766 Press the trip button found on the RCD to determine if it trips or otherwise This test would
not be able to determine the sensitivity of the RCD nor the time taken for it to trip
iv Test Method 2
1048766 Use a RCD Tester
This equipment is equipped with a 13A plug which can be connected to a 13A socket outlet Select the
RCD sensitivity to be the same as the sensitivity of the RCD to be tested to determine if the RCD can
trip The time to trip shall not exceed 40 mS
1048766 Test method ndash
a) Position the selection switch in accordance with the sensitivity of the RCD used
Example 100 mA 01 A
b) Position the operations switch to lsquoNo Triprsquo (frac12 Rated mA = 50) connect the 3 pin plug to
the 13A socket outlet
c) Switch on the 13A socket outlet ndash ensure that the P-N and P-E lights light up This shows that
the polarity is correct (Note if both the lights as above do not light up the test cannot be
continued)
d) Press the test button ndash the reading shows less than 200 millisecond and simultaneously the
lsquotestrsquo light lights up and the P-N and P-E lights do not light up At that instant the RCD will
not trip
e) Move the selection switch to 180o (+ve wave) ndash repeat steps (d) and (e) = 100)
f) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
g) Move the selection switch to 0o (-ve wave)
h) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
i) The above test is repeated until a near correct reading is obtained
j) Record the test results
k) Change the operations switch to lsquoFast Triprsquo and press the test button ndash RCD will trip within a
time not exceeding 40 mS
l) Repeat a number of times at 0o or 180o
72 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 9 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (DC)
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
73 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Start stop button 240Vac 5A 2
9 Filament lamp (Bulb ) 240Vac 40W 3
10 Overload Relay 415V 20A 3
11 Three phase induction motor 5 hp 3
12 Single phase step down transformer 2500VA 1
13 Single core PVC insulated Cable 1mm 2 As required
14 Single core PVC insulated Cable 25mm 2 As required
15 DIN rail 35 mm As required
16 PVC type Cable tray 50 mm x 50 mm As required
17 Cable ties 4 ldquo As required
18 Flexible wires 05 mm As required
19 PVC Connectors 5 A amp 20 A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the schematic
diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a optional exercise
i Simple DOL starter
ii Forward reverse DOL starter
iii Forward Reverse Dahlander motor
iv Three motors operated in sequence by DOL starter operated by manual push
button or time delay relay
74 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
a One loop per-cycle
b Continuous operation in a loop
c optional circuit design to represent the same task
v Only one out of three motors to be operated at a time (quiz)
4 Test the functionality of completed project
LESSON 10 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (AC)
75 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 1
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Lamp point 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
76 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
11 Overload Relay 415V 20A 3
12 Three phase induction
motor
5 hp 3
13 Single core PVC insulated
Cable
1mm 2 As required
14 Single core PVC insulated
Cable
25mm 2 As required
15 DIN rail 35 mm As required
16 PVC type Cable tray 50 mm x 50 mm As required
17 Cable ties 4 ldquo As required
18 Flexible wires 05 mm As required
19 PVC Connectors 5 A amp 20 A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the
schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram optional exercise
4 Simple DOL starter
5 Forward reverse DOL starter
6 Test the functionality of completed project
77 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 1
78 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
cm
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Indicating light 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
11 Overload Relay 415V 20A 3
12 Three phase induction motor 5 hp 3
13 Single phase step down
transformer
2500VA 1
14 Single core PVC insulated
Cable
1mm 2 As required
15 Single core PVC insulated
Cable
25mm 2 As required
16 DIN rail 35 mm As required
17 PVC type Cable tray 50 mm x 50 mm As required
18 Cable ties 4 ldquo As required
19 Flexible wires 05 mm As required
20 PVC Connectors 5 A amp 20 A 240 V As required
21 Single pole MCB 6A 240 V 1
22 Single pole MCB 2A 240 V 1
23 Triple pole MCB 20A 415 V 1
24 Mounting board 30 cm x 40 cm x 3
cm
1
25 Relay cw 11 pin socket 10 A 240 Vac 2
26 Time delay relay 10 A 240 Vac 3
27 Triple pole Contactor 20A 240Vac 3
28 Batten type Lamp holder 240Vac 10 A 3
29 Start stop button 240Vac 10A 2
30 Indicating light (Bulb ) 240Vac 25W 3
31 Overload Relay 415V 20A 1
32 Three phase dahlander type
induction motor
5 hp 1
33 Single phase step down
transformer
24024Vac
2500VA
1
79 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
34 Single core PVC insulated
Cable
1mm 2 As required
35 Single core PVC insulated
Cable
25mm 2 As required
36 DIN rail 35 mm As required
37 PVC type Cable tray 50 mm x 50 mm As required
38 Cable ties 4 ldquo As required
39 Flexible wires 075 mm As required
40 PVC Connectors 5 A amp 20 A 240 V As required
41 Terminal block 20A 240Vac As required
Procedures
5 Identify each component according to specification and quantity required from the schematic
diagram attached
6 Test the functionality of each component by using multi-meter or power supply whichever
applicable
7 Wire component according to circuit diagram
8 Three motors operated in sequence by DOL starter operated by manual push button or time
delay relay
a One loop per-cycle
b Continuous operation in a loop
c optional circuit design to represent the same task
d Only one out of three motors to be operated at a time (quiz)
9 Test the functionality of completed project
80 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
BASIC DESIGN INDUSTRIAL MOTOR CONTROL (SEQUENCE CONTROL)
THREE PHASE INDUCTION MOTOR OPERATED IN SEQUENCE BY DIRECT ON LINE
STARTER
LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
81 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
82 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Lcd lamp indicator 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
11 Overload Relay 415V 20A 3
12 Three phase induction motor 5 hp 3
13 Single phase step down transformer 2500VA 1
14 Single core PVC insulated Cable 1mm 2 As required
15 Single core PVC insulated Cable 25mm 2 As required
16 DIN rail 35 mm As required
17 PVC type Cable tray 50 mm x 50 mm As required
18 Cable ties 4 ldquo As required
19 Flexible wires 1 mm Oslash As required
20 PVC Terminal block 10A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the schematic
diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a optional exercise
i Forward Reverse dahlander motor
4 Test the functionality of completed project
83 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
THREE PHASE DAHLANDER TYPE INDUCTION MOTOR OPERATED FORWARD AND
REVERSE OPERATION BY DIRECT ON LINE STARTER
84 ndash 99EASYTECH ENTERPRISE
LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
Introduction
If a motors windings are connected in the star configuration any two phases will be in series across
the supply and hence the line current will be smaller(by 577) than if the windings were connected in
the delta arrangement
Hence larger-type motors with heavy starting currents are first connected in star and then when the
starting currents fall in delta This of course means that all six of the ends of the windings must be
brought to terminations outside the casing (Fig 833)
EZTECH
EZTECH ELECTRICAL INSTALLATION GUIDE
The automatic version of this starter incorporates a timing relay which automatically changes the
connections from star to delta Figs 834 and 835 show the wiring and schematic diagrams for a star
delta starter
Objectives
1 Identify component and the specification
2 Design forward reverse star delta starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
2 ndash 99EASYTECH ENTERPRISE
REV -C
LEGENDMCCB Moulded Case Circuit BreakerTOR Thermal Over Load RelayFOW-C Mains Forward ContactorREV-C Mains Reverse ContactorDC Delta ContactorSC Star ContactorS-SW Mains Selector Switch
SC
V2
W2
U2
DC
V1
W1
U1
TOR
TOR
FOW-C
30A MCCB
TOR
MAIN CIRCUIT FORWARD REVERSE STAR DELTA
RYBN S
-SW
3 PHASEINDUCTION MOTOR
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Relay 10 A 240V 3
5 Triple pole Contactor
6 cw NO NC auxiliary contact
240Vac 20 A 4
7 Overload Relay 415 V 1
8 LED indicator 240vac 5 A 4
9 Start stop button 240Vac 5A 2
10 DIN rail 35 mm As required
11 Flexible wires 1 mm As required
12 Single core PVC insulated
wire
25 mm As required
13 Terminal block 20 A As required
14 Squirrel cage motor 5kW 1
15 5 pin plug and socket 415V 20A 1
16 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
3 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
a Manual star delta
b Manual Forward reverse star delta starter
c Automatic star delta starter
d Automatic Forward reverse star delta starter
4 Test the functionality of completed project
4 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
Objectives
1 Identify component and the specification
2 Design auto transformer starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
5 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Autotransformer starter is used to start a 3 phase induction motor that has a rating between 10 to 15 hp
6 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Autotransformer set 10Kw 415 V 50 Hz 1
5 Triple pole Contactor 240Vac 4
6 Batten type Lamp holder 240 Vac 105 A 4
7 Start stop button 240Vac 10A 4
8 Filament lamp (Bulb ) 240Vac 40W 4
9 DIN rail 35 mm As required
10 Flexible wires 1 mm As required
7 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
11 Single core PVC insulated
wire
25 mm As required
12 Terminal block 20 A As required
13 Squirrel cage motor 10kW 1
14 5 pin plug and socket 415V 20A 1
15 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a open transient autotransformer starter
b close transient autotransformer starter
c Forward reverse autotransformer starter
4 Test the functionality of completed project
8 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
Objectives
1 Identify component and the specification
2 Design rotor resistance starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
9 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Rotor Resistor set 10kW 1
5 Triple pole Contactor 240Vac 20A 4
6 Indicating light 240vac 5 A 4
7 Start stop push button 240Vac 5A 4
8 DIN rail 35 mm As required
9 Flexible wires 1 mm 2 As required
10 Single core PVC insulated wire 25 mm 2 As required
11 Terminal block 20 A As required
12 Slip Ring motor 10kW 1
13 5 pin round 3 phase socket 415V 20A 1
14 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
10 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
4 Test the functionality of completed project
a Dead circuit test b Life circuit test
5 Measure starting and running Amps
LESSON 16
TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
An installation in general will suffer damage
Damage usually occurs on the electric motor control as follows
1 Damage to the main circuit
2 Damage to the control circuit
The cause of the damage
i Overcurrent overload short circuit
ii Leakage current to ground
iii Equipment malfunction
iv The main control circuit
a Trip of main circuit protection devices fire
b Defect of motor terminal such as short circuit fire loose
v The control circuit is not functioning -
a contactor relay relay time overload relay does not work damaged burned
b Loose cable connection disconnected
Detecting and Repairing Damage
Examples of damage are as follows
i Motor does not work
ii Motor function and overload relay trips
iii Motor function but only partially functional control circuit
Methods of detecting damage
Among the known methods necessary to detect damage are as follows
1 Turn off the electricity at the main switch (main switch) in order to avoid any danger during the
work carried out to detect damage
2 Check all the protective gear that controls the motor control main circuit
11 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
3 Make sure the damage function control circuit
4 Check the control circuit according to the schematic circuit diagram of the motor control
5 Check the operation of the control circuit
Note
Use wiring that has been installed on the SYSTEM OF MOTOR CONTROL BOARD by Forward
Reverse control circuit for Star Delta to test and look for damage
SELF-ASSESSMENT QUESTIONS
1 (a) Explain what is meant by the term lsquoback emfrsquo in a motor
(b) Outline the basic differences between series shunt and compound wound dc motors
2 (a) With the aid of diagrams explain how the speed of series shunt and compound-wound motors
may be controlled
(b) A 440V dc shunt-wound motor has a field resistance of 200R and an armature resistance of 06 R
When its speed is 20 rev d second the current drawn from the supply is 122A Calculate its back
emf at this speed If the speed were decreased to 19 revssecond the field flux remaining unchanged
calculate the new back emf and the new armature current
3 A load of 64 kW at 240 V is supplied from the terminals of a shunt-wound dc generator The field
resistance is 180 A Calculate the armature current
4 (a) Explain with the aid of a diagram how a rotating magnetic field may be
(b) What is meant by lsquosynchronous speedrsquo
Calculate the synchronous obtained speed of a 12 pole motor if the supply frequency is 50Hz
5 (a) Explain the action of a synchronous motor
(b) What methods are available to start a synchronous motor Explain with diagrams
6 (a) Explain the action of a cage induction motor
(b) What is meant by the term lsquosliprsquo
Calculate the percentage slip of a six pole induction motor running at 162 revssecond from a 50 Hz
supply
7 Describe with sketches three different ways of starting a single-phase induction motor
12 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
8 Explain with the aid of a sketch the action of a three-phase DOL starter
What are dashpots used for How are remote start and stop buttons connected
9 A I0 kW 240V 50Hz single-phase cage rotor induction motor is 85efficient and has a PF of 068
lagging Calculate the motor current and the value of capacitor required to raise the PF to 093
lagging
10 Calculate the torque developed by an 18 kW four-pole induction motor run at 35 slip from a
50Hz supply
APPENDIX 1
13 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 11
14 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 111
Attachment Reference
httpswwwtlc-directcoukBook621htm
httpwwwstgovmyindexphpms
15 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
ii Determine the consumer load requirements
iii Calculate the maximum load demand and
iv Submit the plans drawings and specifications
The planning flow chart for building wiring installations is as shown in Figure 31
11 Site Visit
The purpose of the site visit is to determine -
i Electrical equipment suitable for use
ii Maximum load demand
iii Single or three phase incoming supply
iv Type of wiring and Equipment arrangement
Determining Consumer Load RequirementsWith the aid of the building floor plans the installation requirements such as the proposed load
placement of electrical equipment and installation design plans can be determined
11 Calculating Maximum Load Demand
The estimate of the maximum load demand is for determining the specifications of the wiring
equipment such as the cables and plans
According to clause 311 of MS IEC 60364 Part 1 to determine the maximum demand for each circuit
while ensuring an economic and reliable design within the permitted voltage drop limits Diversity
factors may be taken into account The maximum current demand calculations for each circuit must be
prepared These details will show the current requirements in amperes for each phase and also assist
in determining the cable sizes
Refer to the Third Schedule (Table A and Table B) and Regulation 11(2) of the Electricity Regulations
1994 to estimate the maximum current demand and the diversity factors that may be used for domestic
installations
12 Submission of the Plans Drawings and Specifications Regulation 65 of the Electricity
Regulations 1994 states that the eligibility to submit plans is as follows -
i Wireman with Single Phase Restriction ndash Low voltage single phase up to 60 A
ii Wireman with Three Phase Restriction ndash Low voltage up to 60A
6 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
2 CONTROL AND PROTECTION SYSTEM FOR ELECTRICAL WIRING
7 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
8 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
21 Selection of Control and Protection System for Electrical Wiring
Control and protection of a wiring is a system of separationisolation and switching together with the
protection system which are needed in every domestic wiring installation
22 Isolation and Switching
Examples of isolation and switching are switches power plugs socket outlets and circuit breakers
Their function is to manually connect and break the supply in a particular circuit without interfering
with other circuits
They also aim to prevent the danger of electrical shocks during maintenance testing fault finding and
repair works
23 Protection
This provides protection from dangers caused by electrical currents such as over current earth
leakage current short circuit lightning etc to the wiring system electrical equipment or consumer
The circuit below shows the isolation and protection devices which must be installed in a domestic
electrical wiring system
1 Current Protection
In general protection from the dangers of current can be divided into two aspects namely
i Overcurrent Protection (Over Load or Short Circuit) Properly rated circuit breakers or fuses suitable
for over load or short circuit protection must be used
9 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
The circuit breakers or fuses must be installed on the live conductors only For three phase circuits all
the circuit breakers or fuses must be combined in one set of circuits
Selection of over current devices must be based on the short circuit fault current levels of the circuit
breaker or main switch (kA)
ii Earth Leakage Current Protection
Properly rated Residual Current Devices (RCD) must be used for protection from earth leakage
currents (to prevent electric shocks)
a) Regulation 36(1) of the Electricity Regulations 1994 states that for a place of public entertainment
protection against earth leakage current must be provided by a residual current device of sensitivity
not exceeding 10 mA
b) Regulation 36(2) of the Electricity Regulations 1994 states that for a place where the floor is likely
to be wet or where the wall or enclosure is of low electrical resistance protection against earth leakage
current must be provided by a residual current device of sensitivity not exceeding 10 mA
c) Regulation 36(3) of the Electricity Regulations 1994 states that for an installation where hand-held
equipment apparatus or appliance is likely to be used protection against earth leakage current must be
provided by a residual current device of sensitivity not exceeding 30 mA and
d) Regulation 36(4) of the Electricity Regulations 1994 states that for an installation other than the
installation in (a) (b) and (c) protection against earth leakage current must be provided by a residual
current device of sensitivity not exceeding 100 mA
CABLE SELECTION
31 Selection of Wiring Cable Type
The selection of the cable size has to take into consideration the following-
i All wiring cables must be PVC or PVCPVC insulated with copper conductors Conductors with
cross sectional areas of 16mm2 or less must be of copper Aluminium conductors are not permitted
Refer to Table 4D1A in Appendix II for the current carrying capacities of copper conductor
ii Cables for swimming pools must be water resistant PE (polyethylene) insulated
10 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
iii The selected cable must be capable of delivering the electrical energy efficiently
iv The cable size allows it to carry the current without heating the cable
v The voltage drop must not exceed 4 of the supply voltage Refer to Table 4D1B in Appendix III
vi The cable insulation must be suitable for the surrounding conditions of the installation such as the
ability to withstand the surrounding temperatures and the ability to provide mechanical protection
vii Each conductor in the installation must be protected from overcurrent by means of overcurrent
protection devices needed to prevent damage to the cable insulation
32 Factors Related to Cable Current Carrying CapacityThe following factors in relation to the current carrying capacity of cables must be taken into
consideration-
i Surface wiring using clips ndash group factor
ii Wiring using conduits ndash space factor 40
iii Wiring using ducts ndash space factor 45
iv Concealed wiring ndash group factor and
v Concealed wiring using ducts ndash surrounding temperature factor
Use of Minimum Cross Sectional Area Rating of Wiring ConductorsThe following are the minimum cross sectional areas of conductors based on their applications-
Use of Protection Conductor Minimum Cross Sectional Area Rating
In Comparison with Phase Conductor Cross Sectional Area
The following table shows the protection conductor minimum cross sectional area in comparison
with the phase conductor cross sectional area
Functions and Colour Identification of Non Flexible Cables
The following table shows the functions and colour identification of non flexible cables
11 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
33 Use of Minimum Cross Sectional Area Rating of Wiring Conductors
The following are the minimum cross sectional areas of conductors based on their applications-
34 Use of Protection Conductor Minimum Cross Sectional Area Rating
In Comparison with Phase Conductor Cross Sectional Area
The following table shows the protection conductor minimum cross sectional area in comparison
with the phase conductor cross sectional area
Use of Minimum Cross Sectional Area Rating of Wiring Conductors
The following are the minimum cross sectional areas of conductors based on their applications-
Use of Protection Conductor Minimum Cross Sectional Area Rating
In Comparison with Phase Conductor Cross Sectional Area
The following table shows the protection conductor minimum cross sectional area in comparison
with the phase conductor cross sectional area
Functions and Colour Identification of Non Flexible CablesThe following table shows the functions and colour identification of non flexible cables
12 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Flexible Cables
i Flexible cables of cross sectional area less than 40 mm2 are used in installations for electrical
accessories such as ceiling roses lamp fixtures or attachments socket plugs for mobile
appliances etc
ii Flexible cables shall not be used for permanent wiring
iii Flexible cables for the permanent use of electrical appliances should not exceed 3 meters in
length
37 Functions and Colour Identification of Flexible Cables
Conductor Insulation and Types of WiringVarious material and insulation layers are used for conductor protection Cable selection in
accordance to insulation layers must be done correctly for the type of the wiring installation as
shown in the table below
Functions and Colour Identification of Non Flexible CablesThe following table shows the functions and colour identification of non flexible cables
3 SELECTION OF WIRING ACCESSORIES
i All wiring accessories to be used have to be of those approved by the Energy Commission and
labeled with labels issued by SIRIM For all wiring using UPVC conduits -
13 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
a) Switches socket outlets 3 pin plugs ceiling roses connectors sockets ndash construction material shall
be of polycarbonate type
iii For all wiring using metal conduits - Switches socket outlets and connectors ndash construction
material shall be of metal clad type and All accessories shall be effectively earthed
iv Switch fuse used in single phase installations shall have the fuse permanently connected and not
move with the fuse
v Fuse switch used in 3 phase domestic installations also has fuse and switch The fuse connector is
installed together to allow the fuse to move simultaneously with the switch
vi Lamp
a) Fluorescent lamps using magnetic ballasts (watt loss not exceeding 6 watts) shall be
equipped with dry paper type capacitor
b) Fluorescent lamps using electronic ballasts or high frequency electronic ballasts do not
need capacitors
c) Outdoor domestic lamp installations shall use weather proof and water proof lamps
d) Submerged light installations (example in swimming pools fountains etc) shall have water
proof lamps with a voltage not exceeding 12 Volt AC
vii Electric water heaters is divided into 2 types namely
1 instantaneous water heaters and
2 stored water heaters (storage tank type)
a) Instantaneous water heaters shall be equipped with a 2 pole control switch and its own
residual current device
b) Storage water heaters (storage tank type) shall be installed with an
Water heaters exceeding 3kW shall be permanently connected to a 20A30A rated circuit
breakerfuse with an isolator switch and residual current device
viii Electric cookers exceeding 3kW shall have its own circuit connected permanently to a 30A rated
circuit breaker or fuse with an isolator switch and cooker control unit incorporated with a 13A socket
outlet Two or more cooker appliances may be installed in the same room within a distance of 2
meters
ix Electric motors (fence gate air conditioners fountains swimming pools fish ponds water
pumps) exceeding 373W but not exceeding 2238W shall be connected permanently to a 20A30A
rated circuit breakerfuse together with an isolator motor starter and 15A socket outlet
14 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
The motor starter shall be of Direct-On-Line type with the appliance together with the contactor
overload relay and on-off control The circuit breakerfuse which controls the motor circuit shall be
capable of withstanding the starting current of the motor
x Electric bells ndash the circuit shall have a push button switch and a ACDC transformer
xi Ceiling fans shall conform to clause 21101 of the MS 12192002 standard with regards to test on
the suspension system of ceiling fans
EARTHING OF ELECTRICAL INSTALLATIONS51 Earthing
Earthing is a connection system between the metallic parts of an electrical wiring system and the
general mass of the earth This will provide an easy path with a low impedence or resistance to earth to
enable the protection system to operate effectively It will thus ensure safety to human
beingsconsumers from the dangers of electric shocks if earth leakage currents are present In general
an electrical installation is earthed because of -
i Safety reasons
ii Protection system requirements
iii Need to limit over voltages
iv Need to provide a path for electrical discharge
v Legal requirements
52 Classification of Earthing
Generally earthing can be divided into 2 parts namely -
i System Earthing
a To isolate the system under fault conditions
b To limit the potential difference between conductors which are not insulated in an area
c To limit the occurrence of over voltages under various conditions
ii Equipment Earthing
Equipment earthing is undertaken to protect human beingsconsumers If a live source comes into
contact with the equipment body electrical energy will flow to the earth without flowing through the
human being consumerrsquos body This is because of the fact that the human body has a greater
resistance compared with the resistance to earth
53 Types and Functions of Earthing Accessories
Earthing accessories are as follows -
i Earthing Electrode
Copper jacketed steel core rods are used as electrodes for domestic wiring
ii Equipotential Bonding
15 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
This is the conductor which is connected between the consumer earthing point and the exposed
metallic part The minimum cable size for this purpose is 10 mm2
iii Protection Conductor
This is the conductor which connects the consumer earthing point with other parts of the installation
which needs earthing Its size is as follows-
a) Same size as the phase cable up to a size of 16mm2
b) 16 mm2 if the phase cable size is between 16 mm2 and 35 mm2
c) Half the size of the phase cable if the size of the phase cable exceeds 35 mm2
54 Earthing Arrangements Using a TT System
i The first alphabet indicates the earthing arrangements from the supply side
ii The second alphabet indicates the earthing arrangement in the consumerrsquos installation
T ndash first Indicates that the supply system has its own earthing arrangements
T ndash second Indicates that all metallic frames of the electrical appliances etc are connected directly to
earth
Parts that are Required to be Earthed
i All metallic structures in the wiring system (non current carrying) such as metallic covers conduits
ducts the armour of catenary wires etc
ii A secondary winding point in a transformer and
iii Frame of metal roof truss
56 Parts that are not Required to be Earthed
i Short isolated metallic parts for mechanical protection of cables which have non metallic sheaths
other than conduits which are connected at entry points between the building and conduits which
protect discharge lamp cables
ii Cable clips for installing cables
iii Metallic covers for lamps
16 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
iv Small metallic parts such as screws and name plates which are isolated by means of insulation
v Metallic lamp parts for filament lamps in water proof floors
57 Termination to Earth
The termination to earth is done as shown in Figure 72
Earth Electrode Resistance
The maximum permitted earth electrode resistance for different types of installations is as shown in
the Table below
Earth electrode for installations protected by RCDs of sensitivity 100mA 10 Ω
Lightning arrestor earth electrode 10 Ω
Legal Requirements
i Sub regulation 12(1) and 12(2) of the Electricity Regulations 1994 state that any electrical wiring in
an installation shall be under the immediate supervision of a Wireman with Single Phase Restriction or
Three Phase Restriction Upon completion the Wireman shall certify a Supervision and Completion
Certificate
ii Sub regulation 13(1) and 13 (2) of the Electricity Regulations 1994 state that the installation shall
be tested by a Wireman with Single Phase Restriction or a Wireman with Three Phase Restriction
authorized to test any installation and who shall certify a Test Certificate for the installation
iii Sub regulation 14(1) of the Electricity Regulations 1994 states that the Supervision and
Completion Certificate and the Test Certificate as in regulations 12 and 13 shall be in Forms G and H
respectively as prescribed in the First Schedule
17 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
4 SAFETY REQUIREMENTS FOR ELECTRICAL WIRING WORKS IN RESIDENTIAL BUILDINGS
61 Safety Requirements
Safety requirements for electrical wiring works have to be followed to eliminate any accidents which
can result in physical damage or loss of life or property Failure to meet the safety regulations may
result in workers consumers or the public being inflicted with electrical shocks
In addition to this safety steps will also encourage workers or electricity consumers who are
disciplined and who always give importance to safety
62 Safety Steps
Safety requirements have to be followed whenever electrical works are undertaken in a residential
building
i Personal Safety
a Use suitable personal protection equipment as needed such as safety shoes gloves safety helmet
etc when at the work place
b Use safety clothing suitable for the work to be undertaken
c Do not wear jewellery or decorative items such as rings watches chains etc while carrying out
electrical works
ii Safety at the Work Place
a Acquire knowledge about the dangers of electrical works that is to be undertaken and how to deal
with those dangers
b Always adhere to the safety regulations which have been set for the work place
c Ensure that the electricity supply is switched off before carrying out the works
d Acquire the needed knowledge and practice a cautious and calm attitude while working ensure
cleanliness in and around fellow workers
e While working at elevated places the worker should always use suitable equipment such as wooden
or aluminium ladders iron scaffoldings or platforms safety belts or other equipment needed to ensure
that the work can be undertaken safely
f Use electrical equipment which is operational and safe to be used and ensure that the supply for it is
being supplied through a residual current device (RCD) with a sensitivity of 30 mA
g Ensure that exposed temporary supply electrical cables have mechanical protection
h If inflammable or corrosive material is present necessary safety steps have to be undertaken as
required by the relevant safety regulations
63 Dangers of Electrical Shocks
i Electrical Shock
Electrical shocks can occur due to direct or indirect contact
a Direct Contact
18 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Direct contact occurs when the worker or consumer receives an electrical shock on touching directly a
live conductor or cable
b Indirect Contact
Here the electric shock occurs due to contact with a part which is connected to the electrical
installation and not to a direct contact with a live cable or conductor possibly due to damages in the
appliance or insulation resulting in leakages of current
Why Electric Shocks Occura Unsafe Work Method or Action Undertaking Electrical Work Without Disconnecting the
Supply
Maintenance or circuit testing work done without disconnecting the supply will have a high possibility
of electrical shocks occurring
bull Not Following Safe Work Procedures
To eliminate the occurrence of electrical shocks each worker has to always follow safe work
procedures which are set by regulations and standards
b Defects in the Electrical System
i Leakage Current
Leakage currents or earth leakage currents can result in the metallic frames becoming live and
energised This can give rise to the danger of electrical shock to the worker consumer or the public if
they hold or come into contact with the metallic frame
ii Exposed Conductor or Disconnected Cable
Exposed conductors or cables which are broken and are alive (energised) can result in electrical shock
when touched The supply source must be immediately isolated or switched off and a report must be
made to the responsible entity
64 First Aid and Basic Pulmonary Resuscitation
i First Aid
First aid is the initial assistance given to a person who has met with an accident is sick or is injured to
prevent the condition of the victim from becoming more serious while awaiting the arrival of the
paramedics (ambulance) or before being brought to the hospital
i Pulmonary Resuscitation
Pulmonary resuscitation has to be undertaken to assist the victim who has breathing difficulties as a
result of being drowned receiving an electrical shock etc Pulmonary resuscitation has to be carried
out in accordance to the correct method as stated in the first aid manuals issued by accredited first aid
bodies
ii First Aid Box
19 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
A first aid box has to be provided by the building owner construction site supervisor or brought
personally by the worker under the supervision of the responsible person
65 Training Programme
The management shall conduct periodic training programmes for the workers with regards to work
safety on aspects including the following -
i Dangers of electrical work being undertaken and how to control those dangers
ii The safety regulations set for the work place and
iii First aid procedures
66 Fire Prevention
Fire Extinguisher A suitable functioning fire extinguisher to control fires has to be made available at
the work place at all times
67 Competent Person
The Electricity Regulations 1994 require that all electrical work has to be undertaken by or under the
direct supervision of a competent person registered with the Energy Commission Besides that the
electrical contractor undertaking the electrical work has also to be registered with the Energy
Commission The installation owner thus has to ensure that the appointed electrical contractor is
registered with the Energy Commission and that the registration is still valid
INSTALLATION CIRCUITS AND SYSTEMS1 Block diagrams
These show using squares rectangles etc the sequence of a system without too much technical detail
eg Figures 1517 and 1526
2 Layout diagrams
These are very similar to block diagrams but they indicate more technical detail and tend to show
items in their correct geographical location (eg Figures 1518 and 1519)
3 Circuitschematic
These show how a circuit functions and takes no account of exact locations of terminals or equipment
(eg Figures 1528 1529 1532 1534 etc)
4 Wiring diagram
These indicate how a circuit or system is physically wired (eg Figures 152 154 156 etc)
Most induction motors are started directly on line but when very large motors are started that way
they cause a disturbance of voltage on the supply lines due to large starting current surges To limit the
starting current surge large induction motors are started at reduced voltage and then have full supply
voltage reconnected when they run up to near rotated speed Two methods are used for reduction of
starting voltage are star delta starting and auto transformer stating
20 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Working Principal of Star-Delta Starter
This is the reduced voltage starting method Voltage reduction during star-delta starting is achieved by
physically reconfiguring the motor windings as illustrated in the figure below During starting the
motor windings are connected in star configuration and this reduces the voltage across each winding 3
This also reduces the torque by a factor of three After a period of time the winding are reconfigured as
delta and the motor runs normally
StarDelta starters are probably the most common reduced voltage starters They are used in
an attempt to reduce the start current applied to the motor during start as a means of reducing the
disturbances and interference on the electrical supply
Traditionally in many supply regions there has been a requirement to fit a reduced voltage
starter on all motors greater than 5HP (4KW) The StarDelta (or WyeDelta) starter is one of the
lowest cost electromechanical reduced voltage starters that can be applied
The StarDelta starter is manufactured from three contactors a timer and a thermal overload
The contactors are smaller than the single contactor used in a Direct on Line starter as they are
controlling winding currents only The currents through the winding are 1root 3 (58) of the
current in the line
There are two contactors that are close during run often referred to as the main contractor and
the delta contactor These are AC3 rated at 58 of the current rating of the motor The third
contactor is the star contactor and that only carries star current while the motor is connected in star
The current in star is one third of the current in delta so this contactor can be AC3 rated at one
third (33) of the motor rating
Star-delta Starter Consists following units
1) Contactors (Main star and delta contactors) 3 Norsquos (For Open State Starter) or 4 Norsquos (Close
Transient Starter)
2) Time relay (pull-in delayed) 1 No
3) Three-pole thermal over current release 1No
4) Fuse elements or automatic cut-outs for the main circuit 3 Nos
5) Fuse element or automatic cut-out for the control circuit 1No
Power Circuit of Star Delta Starter
1 The main circuit breaker serves as the main power supply switch that supplies electricity to the
power circuit
2 The main contactor connects the reference source voltage R Y B to the primary terminal of the
motor U1 V1 W1
21 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
3 In operation the Main Contactor (KM3) and the Star Contactor (KM1) are closed initially and
then after a period of time the star contactor is opened and then the delta contactor (KM2) is
closed The control of the contactors is by the timer (K1T) built into the starter The Star and Delta
are electrically interlocked and preferably mechanically interlocked as well In effect there are
four states
4 The star contactor serves to initially short the secondary terminal of the motor U2 V2 W2 for the
start sequence during the initial run of the motor from standstill This provides one third of DOL
current to the motor thus reducing the high inrush current inherent with large capacity motors at
startup
5 Controlling the interchanging star connection and delta connection of an AC induction motor is
achieved by means of a star delta or wye delta control circuit The control circuit consists of push
button switches auxiliary contacts and a timer
Control Circuit of Star-Delta Starter (Open Transition)
1 The ON push button starts the circuit by initially energizing Star Contactor Coil (KM1) of star
circuit and Timer Coil (KT) circuit
2 When Star Contactor Coil (KM1) energized Star Main and Auxiliary contactor change its
position from NO to NC
3 When Star Auxiliary Contactor (1)( which is placed on Main Contactor coil circuit )became
NO to NC itrsquos complete The Circuit of Main contactor Coil (KM3) so Main Contactor Coil
energized and Main Contactorrsquos Main and Auxiliary Contactor Change its Position from NO
To NC This sequence happens in a friction of time
4 After pushing the ON push button switch the auxiliary contact of the main contactor coil (2)
which is connected in parallel across the ON push button will become NO to NC thereby
providing a latch to hold the main contactor coil activated which eventually maintains the
control circuit active even after releasing the ON push button switch
5 When Star Main Contactor (KM1) close its connect Motor connects on STAR and itrsquos
connected in STAR until Time Delay Auxiliary contact KT (3) become NC to NO
6 Once the time delay is reached its specified Time the timerrsquos auxiliary contacts (KT)(3) in
Star Coil circuit will change its position from NC to NO and at the Same Time Auxiliary
contactor (KT) in Delta Coil Circuit(4) change its Position from NO To NC so Delta coil
energized and Delta Main Contactor becomes NO To NC Now Motor terminal connection
change from star to delta connection
7 A normally close auxiliary contact from both star and delta contactors (5amp6)are also placed
opposite of both star and delta contactor coils these interlock contacts serves as safety
switches to prevent simultaneous activation of both star and delta contactor coils so that one
22 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
cannot be activated without the other deactivated first Thus the delta contactor coil cannot be
active when the star contactor coil is active and similarly the star contactor coil cannot also
be active while the delta contactor coil is active
8 The control circuit above also provides two interrupting contacts to shutdown the motor
The OFF push button switch break the control circuit and the motor when necessary The
thermal overload contact is a protective device which automatically opens the STOP Control
circuit in case when motor overload current is detected by the thermal overload relay this is to
prevent burning of the motor in case of excessive load beyond the rated capacity of the motor
is detected by the thermal overload relay
9 At some point during starting it is necessary to change from a star connected winding to a
delta connected winding Power and control circuits can be arranged to this in one of two
ways ndash open transition or closed transition
What is Open or Closed Transition Starting
(1) Open Transition Starters
Discuss mention above is called open transition switching because there is an open state between
the star state and the delta state
In open transition the power is disconnected from the motor while the winding are reconfigured via
external switching
When a motor is driven by the supply either at full speed or at part speed there is a rotating
magnetic field in the stator This field is rotating at line frequency The flux from the stator field
induces a current in the rotor and this in turn results in a rotor magnetic field
When the motor is disconnected from the supply (open transition) there is a spinning rotor within
the stator and the rotor has a magnetic field Due to the low impedance of the rotor circuit the time
constant is quite long and the action of the spinning rotor field within the stator is that of a
generator which generates voltage at a frequency determined by the speed of the rotor When the
motor is reconnected to the supply it is reclosing onto an unsynchronized generator and this result
in a very high current and torque transient The magnitude of the transient is dependent on the
phase relationship between the generated voltage and the line voltage at the point of closure can
be much higher than DOL current and torque and can result in electrical and mechanical damage
Open transition starting is the easiest to implement in terms or cost and circuitry and if the timing
of the changeover is good this method can work well In practice though it is difficult to set the
necessary timing to operate correctly and disconnectionreconnection of the supply can cause
significant voltagecurrent transients
In Open transition there are Four states
23 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 OFF State All Contactors are open
2 Star State The Main [KM3] and the Star [KM1] contactors are closed and the delta [KM2]
contactor is open The motor is connected in star and will produce one third of DOL torque at one
third of DOL current
3 Open State This type of operation is called open transition switching because there is an
open state between the star state and the delta state The Main contractor is closed and the Delta
and Star contactors are open There is voltage on one end of the motor windings but the other end
is open so no current can flow The motor has a spinning rotor and behaves like a generator
4 Delta State The Main and the Delta contactors are closed The Star contactor is open The
motor is connected to full line voltage and full power and torque are available
(2) Closed Transition StarDelta Starter
There is a technique to reduce the magnitude of the switching transients This requires the use of a
fourth contactor and a set of three resistors The resistors must be sized such that considerable
current is able to flow in the motor windings while they are in circuit
The auxiliary contactor and resistors are connected across the delta contactor In operation just
before the star contactor opens the auxiliary contactor closes resulting in current flow via the
resistors into the star connection Once the star contactor opens current is able to flow round
through the motor windings to the supply via the resistors These resistors are then shorted by the
delta contactor If the resistance of the resistors is too high they will not swamp the voltage
generated by the motor and will serve no purpose
In closed transition the power is maintained to the motor at all time This is achieved by
introducing resistors to take up the current flow during the winding changeover A fourth
contractor is required to place the resistor in circuit before opening the star contactor and then
removing the resistors once the delta contactor is closed These resistors need to be sized to carry
the motor current In addition to requiring more switching devices the control circuit is more
complicated due to the need to carry out resistor switching
In Close transition there are Four states
1 OFF State All Contactors are open
2 Star State The Main [KM3] and the Star [KM1] contactors are closed and the delta [KM2]
contactor is open The motor is connected in star and will produce one third of DOL torque at one
third of DOL current
Star Transition State The motor is connected in star and the resistors are connected across the
delta contactor via the aux [KM4] contactor
24 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Closed Transition State The Main [KM3] contactor is closed and the Delta [KM2] and Star
[KM1] contactors are open Current flows through the motor windings and the transition resistors
via KM4
Delta State The Main and the Delta contactors are closed The transition resistors are shorted out
The Star contactor is open The motor is connected to full line voltage and full power and torque
are available
Effect of Transient in Starter (Open Transient starter)
It is Important the pause between star contactor switch off and Delta contactor switch is on correct
This is because Star contactor must be reliably disconnected before Delta contactor is activated It
is also important that the switch over pause is not too long
For 415v Star Connection voltage is effectively reduced to 58 or 240v The equivalent of 33
that is obtained with Direct Online (DOL) starting
If Star connection has sufficient torque to run up to 75 or 80 of full load speed then the motor
can be connected in Delta mode
When connected to Delta configuration the phase voltage increases by a ratio of V3 or 173 The
phase currents increase by the same ratio The line current increases three times its value in star
connection
During transition period of switchover the motor must be free running with little deceleration
While this is happening ldquoCoastingrdquo it may generate a voltage of its own and on connection to the
supply this voltage can randomly add to or subtract from the applied line voltage This is known as
transient current Only lasting a few milliseconds it causes voltage surges and spikes Known as
a changeover transient
Size of each part of Star-Delta starter
(1) Size of Over Load Relay
For a star-delta starter there is a possibility to place the overload protection in two positions in the
line or in the windings
Overload Relay in Line
In the line is the same as just putting the overload before the motor as with a DOL starter
The rating of Overload (In Line) = FLC of Motor
Disadvantage If the overload is set to FLC then it is not protecting the motor while it is in delta
(setting is x1732 too high)
Overload Relay in Winding
25 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
In the windings means that the overload is placed after the point where the wiring to the contactors
are split into main and delta The overload then always measures the current inside the windings
The setting of Overload Relay (In Winding) =058 X FLC (line current)
Disadvantage We must use separate short circuit and overload protections
(2) Size of Main and Delta Contractor
1 There are two contactors that are close during run often referred to as the main contractor and
the delta contactor These are AC3 rated at 58 of the current rating of the motor
Size of Main Contactor= IFL x 058
(3) Size of Star Contractor
The third contactor is the star contactor and that only carries star current while the motor is
connected in star The current in star is 1 radic3= (58) of the current in delta so this contactor can
be AC3 rated at one third (33) of the motor rating
Size of Star Contactor= IFL x 033
Motor Starting Characteristics of Star-Delta Starter
Available starting current 33 Full Load Current
Peak starting current 13 to 26 Full Load Current
Peak starting torque 33 Full Load Torque
Advantages of Star-Delta starter
The operation of the star-delta method is simple and rugged
It is relatively cheap compared to other reduced voltage methods
Good TorqueCurrent Performance
It draws 2 times starting current of the full load ampere of the motor connected
Disadvantages of Star-Delta starter
Low Starting Torque (Torque = (Square of Voltage) is also reduce)
Break In Supply ndash Possible Transients
Six Terminal Motor Required (Delta Connected)
It requires 2 set of cables from starter to motor
It provides only 33 starting torque and if the load connected to the subject motor requires higher
starting torque at the time of starting than very heavy transients and stresses are produced while
changing from star to delta connections and because of these transients and stresses many
electrical and mechanical break-down occurs
26 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
In this method of starting initially motor is connected in star and then after change over the motor
is connected in delta The delta of motor is formed in starter and not on motor terminals
High transmission and current peaks When starting up pumps and fans for example the load
torque is low at the beginning of the start and increases with the square of the speed When
reaching approx 80-85 of the motor rated speed the load torque is equal to the motor torque and
the acceleration ceases To reach the rated speed a switch over to delta position is necessary and
this will very often result in high transmission and current peaks In some cases the current peak
can reach a value that is even bigger than for a DOL start
Applications with a load torque higher than 50 of the motor rated torque will not be able to start
using the start-delta starter
Low Starting Torque The star-delta (wye-delta) starting method controls whether the lead
connections from the motor are configured in a star or delta electrical connection The initial
connection should be in the star pattern that results in a reduction of the line voltage by a factor of
1radic3 (577) to the motor and the current is reduced to 13 of the current at full voltage but the
starting torque is also reduced 13 to 15 of the DOL starting torque
The transition from star to delta transition usually occurs once nominal speed is reached but is
sometimes performed as low as 50 of nominal speed which make transient Sparks
Features of star-delta starting
1 For low- to high-power three-phase motors
2 Reduced starting current
3 Six connection cables
4 Reduced starting torque
5 Current peak on changeover from star to delta
6 Mechanical load on changeover from star to delta
Application of Star-Delta Starter
The star-delta method is usually only applied to low to medium voltage and light starting
Torque motors
The received starting current is about 30 of the starting current during direct on line start and the
starting torque is reduced to about 25 of the torque available at a DOL start This starting
method only works when the application is light loaded during the start If the motor is too heavily
27 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
loaded there will not be enough torque to accelerate the motor up to speed before switching over
to the delta position
LESSON 1 WIRING SYSTEM OF SINGLE PHASE DISTRIBUTION BOARD
Introduction
28 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
29 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
30 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
31 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 2 WIRING SYSTEM OF SINGLE PHASE LIGHTING CIRCUIT Introduction
Objectives
1 Identify component and the specification
2 Wire component according to the schematic diagram
3 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Wiring bay Perforated metal 180 cm x 180 cm 1
2 Cut out fuse 63 A 240 V 1
3 Neutral link 1
4 Single pole one way switch cw
switch box
5A 240Vac 4
5 single pole two way switch cw
switch box
5A 240Vac 2
6 RCCB In = 40 A Tripping current
100mA240 Vac 50 Hz
1
7 Main switch 32 A 240V 1
8 kWatthour meter 40 A 240 Vac 1
9 Single pole MCB 6A 240 Vac 1
10 Self tapping Wood screw As required
11 DIN rail 35 mm width As required
32 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
12 PVC trunking 50 mm x 50 mm As required
13 Terminal blocks 5 A As required
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
1 One way switch to control one lamp
2 One way switch to control two lamps
3 Two of two way switch to control one lamp
4 Two of single pole two way switch and one of an intermediate switch to control one
lamp
5 One unit of ceiling fan and fan regulator to be controlled by one way switch
4 Test the functionality of completed project
LESSON 3ndash WIRING SYSTEM OF SINGLE PHASE POWER CIRCUIT Introduction
33 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
34 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify types of component and its specification
2 Wire component according to the schematic diagram given
3 Test the functionality of the circuit dead circuit test life circuit test
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board Perforated Metal 1
2 kWh meter 240 V 40 A 1
3 Socket outlet 13A 240Vac 4
4 RCCB 40A Trip Amps
30mA240 Vac
1
5 3 pin socket 240Vac 13A 4
6 Single pole MCB 20A 240 V 2
7 DOL starter 1 kW 240Vac 2
8 1 phase induction motor 2Hp 240 Vac 1
9 Cooker control unit 4kW 240Vac 1
10 Water heater point 4kW 240 Vac 1
11 DIN rail 35 mm As required
12 PVC casing 20mm As required
13 Flexible wires 05 mm As required
14 Terminal block 10 A As required
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Wire two unit of 13 A socket outlet in radial circuit
3 Wire four units of 13 A socket outlet in ring circuit
4 Wire one unit DOL starter for air-conditioner point
5 Wire one unit of cooker control unit point
6 Wire one unit of water heater point
7 Test the functionality of each component by using mmeter or power supply whichever
applicable
8 Wire component according to circuit diagram
9 Test the functionality of completed project dead circuit test life circuit test
Note
35 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Ensure that the correct rating of protection device and size of wire used
LESSON 4ndash CONDUIT BENDING AND TRUNKING FABRICATION TECHNIQUE
Common fitting used in an industrial wiring
Cutting and threading the condute
36 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
37 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
38 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify conduit fitting and the specification
2 Measure and Cut steel conduit according to specified dimension
3 Bend and fabricate conduit at 45 90 according to layout diagram
4 Wire component according to the schematic diagram
5 Test the functionality of the circuit
39 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Conduit Bender Oslash 19 mm ( frac34 ldquo) 1
2 Measuring Tape 3 metre 1
3 Hacksaw frame and blade 30cm 1
4 Conduit cutter 1
5 Pipe Vise 1
6 Pipe Wrench 1
7 Ratchet Dies 20 mm 1
8 Metal trunking 50 mm x 50 mm 1
9 GI conduit 20mm 1
10 End box 20 mm 1
11 Flexible wires 05 mm As required
12 Connectors 5 A As required
13 Single core PVC ins Cable 25 mm 2 As required
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Wire two unit of 13 A socket outlet in radial circuit
3 Wire four unit of 13 A socket outlet in ring circuit
4 Wire one unit DOL starter for air-conditioner point
5 Wire one unit of cooker control unit point
6 Wire one unit of water heater point
7 Test the functionality of each component by using multimeter or power supply whichever
applicable
8 Wire component according to circuit diagram
9 Test the functionality of completed project
Note
Ensure that the rating of protection device and size of wire
K prior to 31 March
2004 (BS 7671)
(formerly)
bare conductor
sleeved at terminations (formerly)
40 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 5 ndashWIRING SYSTEM OF 1 Oslash LIGHTING AND POWER CIRCUIT
POWER CIRCUITSa Radial circuits
Radial circuits are arranged in the same way as item 1 above in lighting layouts in that each socket
outlet is supplied via the previous one
Points to note
1 The number of socket outlets complying with BS 1363 is unlimited for a floor area of up to 50m 2 if
the circuit protection is a 30 A or 32 A cartridge fuse or circuit breaker the cable being 4 mm PVC
copper or 25 mm2 mineral insulated (mi)
2 The number of socket outlets is unlimited for a floor area up to 20 m 2 with any type of circuit
protection of 20 A using 25 mm2 PVC copper cable or 15 mm2 mi
3 The total number of fused spurs is unlimited
b ring final circuits
These circuits are the same as radial circuits except that the final socket outlet is wired back to the
supply position In effect any outlet is supplied from two directions (Fig 152)
Points to note
1 Every twin-socket outlet counts as two single-socket outlets
2 The number of non-fused spurs must not exceed the total number of points on the ring Fig 158
shows seven points on the ring and five spurs
3 The fuse rating of a fused spur box must not exceed 13 A and the current rating of all points supplied
by the fused spur must not exceed 13 A
4 Non-fused spurs must supply no more than one single or one double socket on the ring Fig 158
shows seven points on the ring and five spurs rating of all points supplied by the fused spur must not
exceed 13 A or one stationary appliance
CapacityMain conductor size
copper (mm2)
Earth conductor
size (mm2)
Circuit breaker
capacity (A)
Up to 600 W 15 15 6
600ndash1200 W 1525 15 10
1200ndash1800 W 254 25 16
41 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Ring circuit
(floor area 100 m2)25 15 3032
A2 radial circuit
(floor area 75 m2)40 25 3032
A3 radial circuit
(floor area 50 m2)25 15 20
Air conditioner (15 tonne) 60 60 3032
Cooker 60 60 3032
Water heater 40 40 20
Objectives
1 Identify component and the specification
2 Wire component according to the schematic diagram
3 Test the functionality of the circuit
42 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board Perforated 1
2 Cut out fuse and neutral link 60A 240V 1each
3 kWh meter 240V 40A 1
4 Switched Socket outlet 13A 240Vac 4
5 Single pole two way switch cw switch
box
5A 240Vac 2
6 RCCB ELCB 63 A Tripping current 100mA
415 Vac
1
7 3 pin plug 240Vac 13A 4
8 Single pole MCB 20 A 2
9 Single pole MCB 6A 1
10 Single pole MCB 20A 2
11 DOL starter 240Vac 2
12 1 phase induction motor 2hp 240 Vac 1
13 Self tapping Wood screw As required
14 DIN rail Stainless steel allum35 mm As required
15 PVC pipe 20mm dia As required
16 End box 20 mm dia 4
17 Flexible wires 05 mm 2 As required
18 Connectors 5 A As required
Procedures
43 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
4 Test the functionality of completed project
LESSON 6 ndash WIRING SYSTEM OF 3 Oslash DISTRIBUTION BOARD
Introduction
44 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
45 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
46 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
47 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
48 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify each component and the specification
2 Wire component according to the schematic diagram given
3 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting Board 450 x 600 mm Perforated metal 1
2 5 pin round socket and plug 415V ac 32A 1
3 Cut out fuse 60 A 3
4 Neutral link 1
5 kWatt hour meter 415V 60A 1
6 ELCB RCCB 3P+N In=63A415 Vac I trip= 300mA 1
7 ELCB RCCB 3P+N In=63A415 Vac I trip= 30mA 1
8 Single pole MCB 6A 240 V 3
9 Single pole MCB 20A 240 V 3
10 DOL starter 20 A 240Vac 2
11 Socket outlet 15 A 240 Vac 1
12 Switched Socket outlet 13 A 240 Vac 3
13 Led indicating light 5A 240 Vac 3
14 Single pole 4 gang 1 way switch 5A 240 Vac 2
15 Single pole 2 way switch 5A 240 Vac 2
16 1 phase induction motor 1 kW 240Vac 1
17 Metal trunking 30 mm x30 mm As required
18 Self tapping Wood screw 4 mm x 20 mm As required
19 DIN rail 25 mm x 1mm
20 GI steel rigid conduit 20mm As required
21 Flexible conduit 20mm As required
22 End box 20 mm 4
23 Flexible wires 05 mm 2 As required
24 Single core PVC insulated wire 15 mm 2 As required
25 Single core PVC insulated wires 25 mm 2 As required
26 Terminal block 10 A As required
Procedures
49 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify each components and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
4 Test the functionality of completed project
1 dead circuit test
2 life circuit
Note Proper earthing should be made
50 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 7 ndash WIRING SYSTEM OF THREE PHASE LIGHTING AND POWER CIRCUIT
51 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
52 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify component and the specification
2 Wire component according to the schematic diagram
3 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting bay Board Perforated metal 180 cm x 180 cm 1
2 k Watt hour meter 415V 60A 1
3 MCCB 415V 60A
4 ELCB RCCB In=60A415 Vac I trip=30mA 1
5 5 pin round Socket and
plug
415Vac 32A 4
6 Single pole MCB 6A 1
7 Triple pole MCB 20A 2
8 Triple pole Main switch 60A 1
9 DOL starter 240Vac 2
10 3 phase induction motor 2hp 415 Vac 1
11 1 phase induction motor 1
12 Metal trunking 30 mm x30 mm As required
13 Self tapping Wood screw 4 mm x 20 mm As required
14 DIN rail 25 mm x 1mm
15 GI steel rigid conduit 20mm As required
16 Flexible conduit 20mm As required
17 End box 20 mm 4
18 Flexible wires 05 mm As required
19 Connectors 10 A As required
Procedures
1 Identify each components and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
4 Test the functionality of completed project
1 dead circuit 2 life circuit test
5 Record the current drawn by the load as connected in star and delta
Note Proper earthing should be made
53 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 8 INSPECTION AND TESTING OF ELECTRICAL INSTALLATION
On completion of a wiring installation a number of tests on the installation have to be conducted to
ascertain that the wiring circuits and connected appliances are safe for use Prior to carrying out the
tests an inspection has to be done The results of the inspectionsupervision and test have to be
presented in Form G (as in Appendix IV) and Form H (as in Appendix V)
To have the test certification as in Form H the following tests shall be conducted
i Continuity Test
ii Insulation Resistance Test
iii Polarity Test
iv Earth Electrode Resistance test and
v Residual Current Device Test
1 Continuity Test
There are 3 main types of continuity tests for the final circuits-
i Protection Conductor Continuity Test
ii Final Ring Circuit Conductor Continuity Test
iii Live and Neutral Conductor Continuity Test
a) Protection Conductor Continuity Test
bull To ascertain that all protection conductors are connected in the correct and effective manner
bull Test equipment ndash Multimeter (Ohm range) or Ohm meter
54 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
bull Test Method
1 1048766 Ensure that the main switch RCD and MCB are open circuited (switched off) and all loads
are disconnected
2 1048766 Connected the test leads as in the Figure 81 The meter reading shall be less than 1 Ω
55 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Final Ring Circuit Conductor Continuity Test
bull To ensure that all conductors around the ring circuit have continuity
bull Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
bull Test Method
1 1048766 Disconnect both the supply source live conductors from the MCB the neutral conductor
from the neutral terminals and the earth conductor from the earth terminal in the distribution
fuse box
2 1048766 Connect the test leads as in the Figure 82 (EE)
3 1048766 Repeat the procedure for (L-L) and (N-N)
4 1048766 The meter reading value shall be less than 1 ohm
56 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Live and Neutral Conductor Continuity Test
a To ensure that each conductor in the circuit has continuity
b Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
2 Test Method
1 1048766 Switch off the Main switch RCD and MCB
2 1048766 Disconnect all loads
3 1048766 Switch on all switches in the circuit
4 1048766 Disconnect the fusesfinal circuit breakers and close the circuit
5 1048766 Carry out the test as shown in Figure 83
6 1048766 The meter reading value shall be less than 1Ω
57 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
58 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
CONTINUITY TEST
Insulation Resistance Test
i Ensure that there is no leakage current between phase conductors phase and neutral conductors and
phase conductor and earth
ii Test the strength of the cable insulation
iii Test Equipment ndash Insulation Resistance Tester operating voltage is 250VDC or 500VDC
iv Test Method
1 1048766 Switch off main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
59 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
4 1048766 Carry out test as in the Table below
5 1048766 Meter reading value shall be less than 1 Megaohm
60 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
61 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Insulation resitance test
62 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
INSULATION RESISTANCE TEST BETWEEN CONDUCTORS AND OPPOSITE POLARITY
Polarity Testi Ensure that each fuse or single pole control and protection device is connected only in the phase
conductor
ii Intermediate contact of Edison screw lamp holder is connected to the phase conductor
iii Ensure that phase neutral and earth conductors at socket outlets are connected at the correct
terminals
iv Test Equipment ndash Multimeter (Ohm range) or Ohm meter
v Test Method
1 1048766 Switch off Main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in Figure 85
63 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
5 1048766 Test switches and single phase control devices at the phase conductors
6 1048766 Test socket outlet connection sources
7 1048766 Test Edison screw lamp holder connections
8 1048766 Meter reading value shall be less than 1 Ω
64 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Polarity test
65 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Earth Electrode Resistance Testi To test the earth electrode resistance
ii To ascertain the suitability of the location of the electrode
iii To ensure that the electrode is not buried within the resistance area of another electrode
iv Test equipment ndash Earth Resistance Tester
v Test method -
1 1048766 Terminal rsquoErsquo is connected to the electrode to be tested (green conductor)
2 1048766 Terminal lsquoPrsquo is connected to the potential spike (yellow conductor) at a distance of 10
meters from the earth electrode
3 1048766 Terminal lsquoCrsquo is connected to the current spike (red conductor) at a distance of 20 meters
from the earth electrode
Earth Electrode Resistance Measurement Method (Figure 86)
This test must be repeated at least three times to ensure that the reading is not affected by interacting
earthing regions
i Record the first reading (Z1) Example Z1 = 10 Ω
ii Move the voltage spike to a distance of 6 meters from the original position Record the second
reading (Z2 ) Example Z2 = 10 Ω
iii Move the voltage spike to a distance of 6 meters from the original position Record the third
reading (Z3) Example Z3 = 10 Ω
66 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Residual Current Device Testi Ensure that the residual current device (RCD) trips within the set time on the occurrence of current
leakage to earth
ii Test Equipment ndash RCD Tester RCCB Tester
iii Test Method 1
1 1048766 Use the Trip Test Button
2 1048766 Press the trip button found on the RCD to determine if it trips or otherwise This test would
not be able to determine the sensitivity of the RCD nor the time taken for it to trip
iv Test Method 2
i 1048766 Use a RCD Tester
ii This equipment is equipped with a 13A plug which can be connected to a 13A socket outlet
Select the RCD sensitivity to be the same as the sensitivity of the RCD to be tested to
determine if the RCD can trip The time to trip shall not exceed 40 mS
iii 1048766 Test method ndash
a) Position the selection switch in accordance with the sensitivity of the RCD used
Example 100 mA 01 A
b) Position the operations switch to lsquoNo Triprsquo (frac12 Rated mA = 50) connect the 3 pin plug to
the 13A socket outlet
67 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
c) Switch on the 13A socket outlet ndash ensure that the P-N and P-E lights light up
This shows that the polarity is correct (Note if both the lights as above do not light up the test cannot
be continued)
d) Press the test button ndash the reading shows less than 200 mS and simultaneously the lsquotestrsquo light lights
up and the P-N and P-E lights do not light up At that instant the RCD will not trip
e) Move the selection switch to 180o (+ve wave) ndash repeat steps (d) and (e) Move the operations
switch to lsquoTriprsquo (Rated mA = 100)
g) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200mS
h) Move the selection switch to 0o (-ve wave)
i) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
j) The above test is repeated until a near correct reading is obtained
k) Record the test results
l) Change the operations switch to lsquoFast Triprsquo and press the test button ndash RCD will trip within a
time not exceeding 40 millisecond
m) Repeat a number of times at 0o or 180o
On completion of a wiring installation a number of tests on the installation have to be conducted to
ascertain that the wiring circuits and connected appliances are safe for use Prior to carrying out the
tests an inspection has to be done the following tests shall be conducted
i Continuity Test
ii Insulation Resistance Test
iii Polarity Test
iv Earth Electrode Resistance test and
v Residual Current Device Test
821 Continuity Test
There are 3 main types of continuity tests for the final circuits-
i Protection Conductor Continuity Test
ii Final Ring Circuit Conductor Continuity Test
68 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
iii Live and Neutral Conductor Continuity Test
a) Protection Conductor Continuity Test
bull To ascertain that all protection conductors are connected in the correct and effective manner
bull Test equipment ndash Multimeter (Ohm range) or Ohm meter
bull Test Method
1 1048766 Ensure that the main switch RCD and MCB are open circuited (switched off) and all loads are
disconnected
2 1048766 Connected the test leads as in the Figure 81
3 1048766 The meter reading shall be less than 1 Ω
Final Ring Circuit Conductor Continuity Test
bull To ensure that all conductors around the ring circuit have continuity
bull Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
bull Test Method
1 1048766 Disconnect both the supply source live conductors from the MCB the neutral conductor
from the neutral terminals and the earth conductor from the earth terminal in the distribution
fuse box
2 1048766 Connect the test leads as in the Figure 82 (EE)
3 1048766 Repeat the procedure for (L-L) and (N-N)
4 1048766 The meter reading value shall be less than 1 ohm Figure 82 - Final Ring Circuit Conductor
Continuity Test Ohm Meter
Disconnect both the supply source cables from mcbfuse
Take readings at earth conductors of both sources and note resistance readings
Live and Neutral Conductor Continuity Test
1 To ensure that each conductor in the circuit has continuity
2 Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
3 Test Method
1 1048766 Switch off the Main switch RCD and MCB
2 1048766 Disconnect all loads
3 1048766 Switch on all switches in the circuit
4 1048766 Disconnect the fusesfinal circuit breakers and close the circuit
5 1048766 Carry out the test as shown in Figure 83
6 1048766 The meter reading value shall be less than 1 ohm Figure 83 - Live and Neutral
Conductor Continuity Test Ohm Meter
Insulation Resistance Test
69 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
i Ensure that there is no leakage current between phase conductors phase and neutral conductors and
phase conductor and earth
ii Test the strength of the cable insulation
iii Test Equipment ndash Insulation Resistance Tester Operating voltage is 250VDC or 500VDC
iv Test Method
1 1048766 Switch off main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in the Table below
5 1048766 Meter reading value shall be less than 1 Megaohm
Polarity Test
i Ensure that each fuse or single pole control and protection device is connected only in the phase
conductor
ii Intermediate contact of Edison screw lamp holder is connected to the phase conductor
iii Ensure that phase neutral and earth conductors at socket outlets are connected at the correct
terminals
iv Test Equipment ndash Multimeter (Ohm range) or Ohm meter
v Test Method
1 1048766 Switch off Main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in Figure 85
5 1048766 Test switches and single phase control devices at the phase conductors
6 1048766 Test socket outlet connection sources
7 1048766 Test Edison screw lamp holder connections
8 1048766 Meter reading value shall be less than 1 Ω
Earth Electrode Resistance Test
i To test the earth electrode resistance
70 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
ii To ascertain the suitability of the location of the electrode
iii To ensure that the electrode is not buried within the resistance area of another electrode
iv Test equipment ndash Earth Resistance Tester
v Test method -
1 1048766 Terminal rsquoErsquo is connected to the electrode to be tested (green conductor)
2 1048766 Terminal lsquoPrsquo is connected to the potential spike (yellow conductor) at a distance of 10
meters from the earth electrode
3 1048766 Terminal lsquoCrsquo is connected to the current spike (red conductor) at a distance of 20 meters
from the earth electrode E P C Electrode 10 meter 10 meter
Figure 86 ndash Earth Electrode Resistance Measurement Test Equipment
Earth Electrode Resistance Measurement Method (Figure 86)
This test must be repeated at least three times to ensure that the reading is not affected by interacting
earthing regions
i Record the first reading (Z1) Example Z1 = 10 Ω
ii Move the voltage spike to a distance of 6 meters from the original position Record the second
reading (Z2) Example Z2 = 10 Ω
iii Move the voltage spike to a distance of 6 meters from the original position Record the third
reading (Z3)
Example Z3 = 10 Ω
Residual Current Device Test
71 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
i Ensure that the residual current device (RCD) trips within the set time on the occurrence of current
leakage to earth
ii Test Equipment ndash RCD Tester RCCB Tester
iii Test Method 1
1 1048766 Use the Trip Test Button
2 1048766 Press the trip button found on the RCD to determine if it trips or otherwise This test would
not be able to determine the sensitivity of the RCD nor the time taken for it to trip
iv Test Method 2
1048766 Use a RCD Tester
This equipment is equipped with a 13A plug which can be connected to a 13A socket outlet Select the
RCD sensitivity to be the same as the sensitivity of the RCD to be tested to determine if the RCD can
trip The time to trip shall not exceed 40 mS
1048766 Test method ndash
a) Position the selection switch in accordance with the sensitivity of the RCD used
Example 100 mA 01 A
b) Position the operations switch to lsquoNo Triprsquo (frac12 Rated mA = 50) connect the 3 pin plug to
the 13A socket outlet
c) Switch on the 13A socket outlet ndash ensure that the P-N and P-E lights light up This shows that
the polarity is correct (Note if both the lights as above do not light up the test cannot be
continued)
d) Press the test button ndash the reading shows less than 200 millisecond and simultaneously the
lsquotestrsquo light lights up and the P-N and P-E lights do not light up At that instant the RCD will
not trip
e) Move the selection switch to 180o (+ve wave) ndash repeat steps (d) and (e) = 100)
f) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
g) Move the selection switch to 0o (-ve wave)
h) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
i) The above test is repeated until a near correct reading is obtained
j) Record the test results
k) Change the operations switch to lsquoFast Triprsquo and press the test button ndash RCD will trip within a
time not exceeding 40 mS
l) Repeat a number of times at 0o or 180o
72 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 9 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (DC)
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
73 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Start stop button 240Vac 5A 2
9 Filament lamp (Bulb ) 240Vac 40W 3
10 Overload Relay 415V 20A 3
11 Three phase induction motor 5 hp 3
12 Single phase step down transformer 2500VA 1
13 Single core PVC insulated Cable 1mm 2 As required
14 Single core PVC insulated Cable 25mm 2 As required
15 DIN rail 35 mm As required
16 PVC type Cable tray 50 mm x 50 mm As required
17 Cable ties 4 ldquo As required
18 Flexible wires 05 mm As required
19 PVC Connectors 5 A amp 20 A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the schematic
diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a optional exercise
i Simple DOL starter
ii Forward reverse DOL starter
iii Forward Reverse Dahlander motor
iv Three motors operated in sequence by DOL starter operated by manual push
button or time delay relay
74 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
a One loop per-cycle
b Continuous operation in a loop
c optional circuit design to represent the same task
v Only one out of three motors to be operated at a time (quiz)
4 Test the functionality of completed project
LESSON 10 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (AC)
75 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 1
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Lamp point 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
76 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
11 Overload Relay 415V 20A 3
12 Three phase induction
motor
5 hp 3
13 Single core PVC insulated
Cable
1mm 2 As required
14 Single core PVC insulated
Cable
25mm 2 As required
15 DIN rail 35 mm As required
16 PVC type Cable tray 50 mm x 50 mm As required
17 Cable ties 4 ldquo As required
18 Flexible wires 05 mm As required
19 PVC Connectors 5 A amp 20 A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the
schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram optional exercise
4 Simple DOL starter
5 Forward reverse DOL starter
6 Test the functionality of completed project
77 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 1
78 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
cm
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Indicating light 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
11 Overload Relay 415V 20A 3
12 Three phase induction motor 5 hp 3
13 Single phase step down
transformer
2500VA 1
14 Single core PVC insulated
Cable
1mm 2 As required
15 Single core PVC insulated
Cable
25mm 2 As required
16 DIN rail 35 mm As required
17 PVC type Cable tray 50 mm x 50 mm As required
18 Cable ties 4 ldquo As required
19 Flexible wires 05 mm As required
20 PVC Connectors 5 A amp 20 A 240 V As required
21 Single pole MCB 6A 240 V 1
22 Single pole MCB 2A 240 V 1
23 Triple pole MCB 20A 415 V 1
24 Mounting board 30 cm x 40 cm x 3
cm
1
25 Relay cw 11 pin socket 10 A 240 Vac 2
26 Time delay relay 10 A 240 Vac 3
27 Triple pole Contactor 20A 240Vac 3
28 Batten type Lamp holder 240Vac 10 A 3
29 Start stop button 240Vac 10A 2
30 Indicating light (Bulb ) 240Vac 25W 3
31 Overload Relay 415V 20A 1
32 Three phase dahlander type
induction motor
5 hp 1
33 Single phase step down
transformer
24024Vac
2500VA
1
79 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
34 Single core PVC insulated
Cable
1mm 2 As required
35 Single core PVC insulated
Cable
25mm 2 As required
36 DIN rail 35 mm As required
37 PVC type Cable tray 50 mm x 50 mm As required
38 Cable ties 4 ldquo As required
39 Flexible wires 075 mm As required
40 PVC Connectors 5 A amp 20 A 240 V As required
41 Terminal block 20A 240Vac As required
Procedures
5 Identify each component according to specification and quantity required from the schematic
diagram attached
6 Test the functionality of each component by using multi-meter or power supply whichever
applicable
7 Wire component according to circuit diagram
8 Three motors operated in sequence by DOL starter operated by manual push button or time
delay relay
a One loop per-cycle
b Continuous operation in a loop
c optional circuit design to represent the same task
d Only one out of three motors to be operated at a time (quiz)
9 Test the functionality of completed project
80 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
BASIC DESIGN INDUSTRIAL MOTOR CONTROL (SEQUENCE CONTROL)
THREE PHASE INDUCTION MOTOR OPERATED IN SEQUENCE BY DIRECT ON LINE
STARTER
LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
81 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
82 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Lcd lamp indicator 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
11 Overload Relay 415V 20A 3
12 Three phase induction motor 5 hp 3
13 Single phase step down transformer 2500VA 1
14 Single core PVC insulated Cable 1mm 2 As required
15 Single core PVC insulated Cable 25mm 2 As required
16 DIN rail 35 mm As required
17 PVC type Cable tray 50 mm x 50 mm As required
18 Cable ties 4 ldquo As required
19 Flexible wires 1 mm Oslash As required
20 PVC Terminal block 10A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the schematic
diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a optional exercise
i Forward Reverse dahlander motor
4 Test the functionality of completed project
83 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
THREE PHASE DAHLANDER TYPE INDUCTION MOTOR OPERATED FORWARD AND
REVERSE OPERATION BY DIRECT ON LINE STARTER
84 ndash 99EASYTECH ENTERPRISE
LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
Introduction
If a motors windings are connected in the star configuration any two phases will be in series across
the supply and hence the line current will be smaller(by 577) than if the windings were connected in
the delta arrangement
Hence larger-type motors with heavy starting currents are first connected in star and then when the
starting currents fall in delta This of course means that all six of the ends of the windings must be
brought to terminations outside the casing (Fig 833)
EZTECH
EZTECH ELECTRICAL INSTALLATION GUIDE
The automatic version of this starter incorporates a timing relay which automatically changes the
connections from star to delta Figs 834 and 835 show the wiring and schematic diagrams for a star
delta starter
Objectives
1 Identify component and the specification
2 Design forward reverse star delta starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
2 ndash 99EASYTECH ENTERPRISE
REV -C
LEGENDMCCB Moulded Case Circuit BreakerTOR Thermal Over Load RelayFOW-C Mains Forward ContactorREV-C Mains Reverse ContactorDC Delta ContactorSC Star ContactorS-SW Mains Selector Switch
SC
V2
W2
U2
DC
V1
W1
U1
TOR
TOR
FOW-C
30A MCCB
TOR
MAIN CIRCUIT FORWARD REVERSE STAR DELTA
RYBN S
-SW
3 PHASEINDUCTION MOTOR
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Relay 10 A 240V 3
5 Triple pole Contactor
6 cw NO NC auxiliary contact
240Vac 20 A 4
7 Overload Relay 415 V 1
8 LED indicator 240vac 5 A 4
9 Start stop button 240Vac 5A 2
10 DIN rail 35 mm As required
11 Flexible wires 1 mm As required
12 Single core PVC insulated
wire
25 mm As required
13 Terminal block 20 A As required
14 Squirrel cage motor 5kW 1
15 5 pin plug and socket 415V 20A 1
16 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
3 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
a Manual star delta
b Manual Forward reverse star delta starter
c Automatic star delta starter
d Automatic Forward reverse star delta starter
4 Test the functionality of completed project
4 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
Objectives
1 Identify component and the specification
2 Design auto transformer starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
5 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Autotransformer starter is used to start a 3 phase induction motor that has a rating between 10 to 15 hp
6 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Autotransformer set 10Kw 415 V 50 Hz 1
5 Triple pole Contactor 240Vac 4
6 Batten type Lamp holder 240 Vac 105 A 4
7 Start stop button 240Vac 10A 4
8 Filament lamp (Bulb ) 240Vac 40W 4
9 DIN rail 35 mm As required
10 Flexible wires 1 mm As required
7 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
11 Single core PVC insulated
wire
25 mm As required
12 Terminal block 20 A As required
13 Squirrel cage motor 10kW 1
14 5 pin plug and socket 415V 20A 1
15 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a open transient autotransformer starter
b close transient autotransformer starter
c Forward reverse autotransformer starter
4 Test the functionality of completed project
8 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
Objectives
1 Identify component and the specification
2 Design rotor resistance starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
9 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Rotor Resistor set 10kW 1
5 Triple pole Contactor 240Vac 20A 4
6 Indicating light 240vac 5 A 4
7 Start stop push button 240Vac 5A 4
8 DIN rail 35 mm As required
9 Flexible wires 1 mm 2 As required
10 Single core PVC insulated wire 25 mm 2 As required
11 Terminal block 20 A As required
12 Slip Ring motor 10kW 1
13 5 pin round 3 phase socket 415V 20A 1
14 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
10 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
4 Test the functionality of completed project
a Dead circuit test b Life circuit test
5 Measure starting and running Amps
LESSON 16
TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
An installation in general will suffer damage
Damage usually occurs on the electric motor control as follows
1 Damage to the main circuit
2 Damage to the control circuit
The cause of the damage
i Overcurrent overload short circuit
ii Leakage current to ground
iii Equipment malfunction
iv The main control circuit
a Trip of main circuit protection devices fire
b Defect of motor terminal such as short circuit fire loose
v The control circuit is not functioning -
a contactor relay relay time overload relay does not work damaged burned
b Loose cable connection disconnected
Detecting and Repairing Damage
Examples of damage are as follows
i Motor does not work
ii Motor function and overload relay trips
iii Motor function but only partially functional control circuit
Methods of detecting damage
Among the known methods necessary to detect damage are as follows
1 Turn off the electricity at the main switch (main switch) in order to avoid any danger during the
work carried out to detect damage
2 Check all the protective gear that controls the motor control main circuit
11 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
3 Make sure the damage function control circuit
4 Check the control circuit according to the schematic circuit diagram of the motor control
5 Check the operation of the control circuit
Note
Use wiring that has been installed on the SYSTEM OF MOTOR CONTROL BOARD by Forward
Reverse control circuit for Star Delta to test and look for damage
SELF-ASSESSMENT QUESTIONS
1 (a) Explain what is meant by the term lsquoback emfrsquo in a motor
(b) Outline the basic differences between series shunt and compound wound dc motors
2 (a) With the aid of diagrams explain how the speed of series shunt and compound-wound motors
may be controlled
(b) A 440V dc shunt-wound motor has a field resistance of 200R and an armature resistance of 06 R
When its speed is 20 rev d second the current drawn from the supply is 122A Calculate its back
emf at this speed If the speed were decreased to 19 revssecond the field flux remaining unchanged
calculate the new back emf and the new armature current
3 A load of 64 kW at 240 V is supplied from the terminals of a shunt-wound dc generator The field
resistance is 180 A Calculate the armature current
4 (a) Explain with the aid of a diagram how a rotating magnetic field may be
(b) What is meant by lsquosynchronous speedrsquo
Calculate the synchronous obtained speed of a 12 pole motor if the supply frequency is 50Hz
5 (a) Explain the action of a synchronous motor
(b) What methods are available to start a synchronous motor Explain with diagrams
6 (a) Explain the action of a cage induction motor
(b) What is meant by the term lsquosliprsquo
Calculate the percentage slip of a six pole induction motor running at 162 revssecond from a 50 Hz
supply
7 Describe with sketches three different ways of starting a single-phase induction motor
12 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
8 Explain with the aid of a sketch the action of a three-phase DOL starter
What are dashpots used for How are remote start and stop buttons connected
9 A I0 kW 240V 50Hz single-phase cage rotor induction motor is 85efficient and has a PF of 068
lagging Calculate the motor current and the value of capacitor required to raise the PF to 093
lagging
10 Calculate the torque developed by an 18 kW four-pole induction motor run at 35 slip from a
50Hz supply
APPENDIX 1
13 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 11
14 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 111
Attachment Reference
httpswwwtlc-directcoukBook621htm
httpwwwstgovmyindexphpms
15 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
2 CONTROL AND PROTECTION SYSTEM FOR ELECTRICAL WIRING
7 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
8 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
21 Selection of Control and Protection System for Electrical Wiring
Control and protection of a wiring is a system of separationisolation and switching together with the
protection system which are needed in every domestic wiring installation
22 Isolation and Switching
Examples of isolation and switching are switches power plugs socket outlets and circuit breakers
Their function is to manually connect and break the supply in a particular circuit without interfering
with other circuits
They also aim to prevent the danger of electrical shocks during maintenance testing fault finding and
repair works
23 Protection
This provides protection from dangers caused by electrical currents such as over current earth
leakage current short circuit lightning etc to the wiring system electrical equipment or consumer
The circuit below shows the isolation and protection devices which must be installed in a domestic
electrical wiring system
1 Current Protection
In general protection from the dangers of current can be divided into two aspects namely
i Overcurrent Protection (Over Load or Short Circuit) Properly rated circuit breakers or fuses suitable
for over load or short circuit protection must be used
9 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
The circuit breakers or fuses must be installed on the live conductors only For three phase circuits all
the circuit breakers or fuses must be combined in one set of circuits
Selection of over current devices must be based on the short circuit fault current levels of the circuit
breaker or main switch (kA)
ii Earth Leakage Current Protection
Properly rated Residual Current Devices (RCD) must be used for protection from earth leakage
currents (to prevent electric shocks)
a) Regulation 36(1) of the Electricity Regulations 1994 states that for a place of public entertainment
protection against earth leakage current must be provided by a residual current device of sensitivity
not exceeding 10 mA
b) Regulation 36(2) of the Electricity Regulations 1994 states that for a place where the floor is likely
to be wet or where the wall or enclosure is of low electrical resistance protection against earth leakage
current must be provided by a residual current device of sensitivity not exceeding 10 mA
c) Regulation 36(3) of the Electricity Regulations 1994 states that for an installation where hand-held
equipment apparatus or appliance is likely to be used protection against earth leakage current must be
provided by a residual current device of sensitivity not exceeding 30 mA and
d) Regulation 36(4) of the Electricity Regulations 1994 states that for an installation other than the
installation in (a) (b) and (c) protection against earth leakage current must be provided by a residual
current device of sensitivity not exceeding 100 mA
CABLE SELECTION
31 Selection of Wiring Cable Type
The selection of the cable size has to take into consideration the following-
i All wiring cables must be PVC or PVCPVC insulated with copper conductors Conductors with
cross sectional areas of 16mm2 or less must be of copper Aluminium conductors are not permitted
Refer to Table 4D1A in Appendix II for the current carrying capacities of copper conductor
ii Cables for swimming pools must be water resistant PE (polyethylene) insulated
10 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
iii The selected cable must be capable of delivering the electrical energy efficiently
iv The cable size allows it to carry the current without heating the cable
v The voltage drop must not exceed 4 of the supply voltage Refer to Table 4D1B in Appendix III
vi The cable insulation must be suitable for the surrounding conditions of the installation such as the
ability to withstand the surrounding temperatures and the ability to provide mechanical protection
vii Each conductor in the installation must be protected from overcurrent by means of overcurrent
protection devices needed to prevent damage to the cable insulation
32 Factors Related to Cable Current Carrying CapacityThe following factors in relation to the current carrying capacity of cables must be taken into
consideration-
i Surface wiring using clips ndash group factor
ii Wiring using conduits ndash space factor 40
iii Wiring using ducts ndash space factor 45
iv Concealed wiring ndash group factor and
v Concealed wiring using ducts ndash surrounding temperature factor
Use of Minimum Cross Sectional Area Rating of Wiring ConductorsThe following are the minimum cross sectional areas of conductors based on their applications-
Use of Protection Conductor Minimum Cross Sectional Area Rating
In Comparison with Phase Conductor Cross Sectional Area
The following table shows the protection conductor minimum cross sectional area in comparison
with the phase conductor cross sectional area
Functions and Colour Identification of Non Flexible Cables
The following table shows the functions and colour identification of non flexible cables
11 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
33 Use of Minimum Cross Sectional Area Rating of Wiring Conductors
The following are the minimum cross sectional areas of conductors based on their applications-
34 Use of Protection Conductor Minimum Cross Sectional Area Rating
In Comparison with Phase Conductor Cross Sectional Area
The following table shows the protection conductor minimum cross sectional area in comparison
with the phase conductor cross sectional area
Use of Minimum Cross Sectional Area Rating of Wiring Conductors
The following are the minimum cross sectional areas of conductors based on their applications-
Use of Protection Conductor Minimum Cross Sectional Area Rating
In Comparison with Phase Conductor Cross Sectional Area
The following table shows the protection conductor minimum cross sectional area in comparison
with the phase conductor cross sectional area
Functions and Colour Identification of Non Flexible CablesThe following table shows the functions and colour identification of non flexible cables
12 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Flexible Cables
i Flexible cables of cross sectional area less than 40 mm2 are used in installations for electrical
accessories such as ceiling roses lamp fixtures or attachments socket plugs for mobile
appliances etc
ii Flexible cables shall not be used for permanent wiring
iii Flexible cables for the permanent use of electrical appliances should not exceed 3 meters in
length
37 Functions and Colour Identification of Flexible Cables
Conductor Insulation and Types of WiringVarious material and insulation layers are used for conductor protection Cable selection in
accordance to insulation layers must be done correctly for the type of the wiring installation as
shown in the table below
Functions and Colour Identification of Non Flexible CablesThe following table shows the functions and colour identification of non flexible cables
3 SELECTION OF WIRING ACCESSORIES
i All wiring accessories to be used have to be of those approved by the Energy Commission and
labeled with labels issued by SIRIM For all wiring using UPVC conduits -
13 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
a) Switches socket outlets 3 pin plugs ceiling roses connectors sockets ndash construction material shall
be of polycarbonate type
iii For all wiring using metal conduits - Switches socket outlets and connectors ndash construction
material shall be of metal clad type and All accessories shall be effectively earthed
iv Switch fuse used in single phase installations shall have the fuse permanently connected and not
move with the fuse
v Fuse switch used in 3 phase domestic installations also has fuse and switch The fuse connector is
installed together to allow the fuse to move simultaneously with the switch
vi Lamp
a) Fluorescent lamps using magnetic ballasts (watt loss not exceeding 6 watts) shall be
equipped with dry paper type capacitor
b) Fluorescent lamps using electronic ballasts or high frequency electronic ballasts do not
need capacitors
c) Outdoor domestic lamp installations shall use weather proof and water proof lamps
d) Submerged light installations (example in swimming pools fountains etc) shall have water
proof lamps with a voltage not exceeding 12 Volt AC
vii Electric water heaters is divided into 2 types namely
1 instantaneous water heaters and
2 stored water heaters (storage tank type)
a) Instantaneous water heaters shall be equipped with a 2 pole control switch and its own
residual current device
b) Storage water heaters (storage tank type) shall be installed with an
Water heaters exceeding 3kW shall be permanently connected to a 20A30A rated circuit
breakerfuse with an isolator switch and residual current device
viii Electric cookers exceeding 3kW shall have its own circuit connected permanently to a 30A rated
circuit breaker or fuse with an isolator switch and cooker control unit incorporated with a 13A socket
outlet Two or more cooker appliances may be installed in the same room within a distance of 2
meters
ix Electric motors (fence gate air conditioners fountains swimming pools fish ponds water
pumps) exceeding 373W but not exceeding 2238W shall be connected permanently to a 20A30A
rated circuit breakerfuse together with an isolator motor starter and 15A socket outlet
14 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
The motor starter shall be of Direct-On-Line type with the appliance together with the contactor
overload relay and on-off control The circuit breakerfuse which controls the motor circuit shall be
capable of withstanding the starting current of the motor
x Electric bells ndash the circuit shall have a push button switch and a ACDC transformer
xi Ceiling fans shall conform to clause 21101 of the MS 12192002 standard with regards to test on
the suspension system of ceiling fans
EARTHING OF ELECTRICAL INSTALLATIONS51 Earthing
Earthing is a connection system between the metallic parts of an electrical wiring system and the
general mass of the earth This will provide an easy path with a low impedence or resistance to earth to
enable the protection system to operate effectively It will thus ensure safety to human
beingsconsumers from the dangers of electric shocks if earth leakage currents are present In general
an electrical installation is earthed because of -
i Safety reasons
ii Protection system requirements
iii Need to limit over voltages
iv Need to provide a path for electrical discharge
v Legal requirements
52 Classification of Earthing
Generally earthing can be divided into 2 parts namely -
i System Earthing
a To isolate the system under fault conditions
b To limit the potential difference between conductors which are not insulated in an area
c To limit the occurrence of over voltages under various conditions
ii Equipment Earthing
Equipment earthing is undertaken to protect human beingsconsumers If a live source comes into
contact with the equipment body electrical energy will flow to the earth without flowing through the
human being consumerrsquos body This is because of the fact that the human body has a greater
resistance compared with the resistance to earth
53 Types and Functions of Earthing Accessories
Earthing accessories are as follows -
i Earthing Electrode
Copper jacketed steel core rods are used as electrodes for domestic wiring
ii Equipotential Bonding
15 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
This is the conductor which is connected between the consumer earthing point and the exposed
metallic part The minimum cable size for this purpose is 10 mm2
iii Protection Conductor
This is the conductor which connects the consumer earthing point with other parts of the installation
which needs earthing Its size is as follows-
a) Same size as the phase cable up to a size of 16mm2
b) 16 mm2 if the phase cable size is between 16 mm2 and 35 mm2
c) Half the size of the phase cable if the size of the phase cable exceeds 35 mm2
54 Earthing Arrangements Using a TT System
i The first alphabet indicates the earthing arrangements from the supply side
ii The second alphabet indicates the earthing arrangement in the consumerrsquos installation
T ndash first Indicates that the supply system has its own earthing arrangements
T ndash second Indicates that all metallic frames of the electrical appliances etc are connected directly to
earth
Parts that are Required to be Earthed
i All metallic structures in the wiring system (non current carrying) such as metallic covers conduits
ducts the armour of catenary wires etc
ii A secondary winding point in a transformer and
iii Frame of metal roof truss
56 Parts that are not Required to be Earthed
i Short isolated metallic parts for mechanical protection of cables which have non metallic sheaths
other than conduits which are connected at entry points between the building and conduits which
protect discharge lamp cables
ii Cable clips for installing cables
iii Metallic covers for lamps
16 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
iv Small metallic parts such as screws and name plates which are isolated by means of insulation
v Metallic lamp parts for filament lamps in water proof floors
57 Termination to Earth
The termination to earth is done as shown in Figure 72
Earth Electrode Resistance
The maximum permitted earth electrode resistance for different types of installations is as shown in
the Table below
Earth electrode for installations protected by RCDs of sensitivity 100mA 10 Ω
Lightning arrestor earth electrode 10 Ω
Legal Requirements
i Sub regulation 12(1) and 12(2) of the Electricity Regulations 1994 state that any electrical wiring in
an installation shall be under the immediate supervision of a Wireman with Single Phase Restriction or
Three Phase Restriction Upon completion the Wireman shall certify a Supervision and Completion
Certificate
ii Sub regulation 13(1) and 13 (2) of the Electricity Regulations 1994 state that the installation shall
be tested by a Wireman with Single Phase Restriction or a Wireman with Three Phase Restriction
authorized to test any installation and who shall certify a Test Certificate for the installation
iii Sub regulation 14(1) of the Electricity Regulations 1994 states that the Supervision and
Completion Certificate and the Test Certificate as in regulations 12 and 13 shall be in Forms G and H
respectively as prescribed in the First Schedule
17 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
4 SAFETY REQUIREMENTS FOR ELECTRICAL WIRING WORKS IN RESIDENTIAL BUILDINGS
61 Safety Requirements
Safety requirements for electrical wiring works have to be followed to eliminate any accidents which
can result in physical damage or loss of life or property Failure to meet the safety regulations may
result in workers consumers or the public being inflicted with electrical shocks
In addition to this safety steps will also encourage workers or electricity consumers who are
disciplined and who always give importance to safety
62 Safety Steps
Safety requirements have to be followed whenever electrical works are undertaken in a residential
building
i Personal Safety
a Use suitable personal protection equipment as needed such as safety shoes gloves safety helmet
etc when at the work place
b Use safety clothing suitable for the work to be undertaken
c Do not wear jewellery or decorative items such as rings watches chains etc while carrying out
electrical works
ii Safety at the Work Place
a Acquire knowledge about the dangers of electrical works that is to be undertaken and how to deal
with those dangers
b Always adhere to the safety regulations which have been set for the work place
c Ensure that the electricity supply is switched off before carrying out the works
d Acquire the needed knowledge and practice a cautious and calm attitude while working ensure
cleanliness in and around fellow workers
e While working at elevated places the worker should always use suitable equipment such as wooden
or aluminium ladders iron scaffoldings or platforms safety belts or other equipment needed to ensure
that the work can be undertaken safely
f Use electrical equipment which is operational and safe to be used and ensure that the supply for it is
being supplied through a residual current device (RCD) with a sensitivity of 30 mA
g Ensure that exposed temporary supply electrical cables have mechanical protection
h If inflammable or corrosive material is present necessary safety steps have to be undertaken as
required by the relevant safety regulations
63 Dangers of Electrical Shocks
i Electrical Shock
Electrical shocks can occur due to direct or indirect contact
a Direct Contact
18 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Direct contact occurs when the worker or consumer receives an electrical shock on touching directly a
live conductor or cable
b Indirect Contact
Here the electric shock occurs due to contact with a part which is connected to the electrical
installation and not to a direct contact with a live cable or conductor possibly due to damages in the
appliance or insulation resulting in leakages of current
Why Electric Shocks Occura Unsafe Work Method or Action Undertaking Electrical Work Without Disconnecting the
Supply
Maintenance or circuit testing work done without disconnecting the supply will have a high possibility
of electrical shocks occurring
bull Not Following Safe Work Procedures
To eliminate the occurrence of electrical shocks each worker has to always follow safe work
procedures which are set by regulations and standards
b Defects in the Electrical System
i Leakage Current
Leakage currents or earth leakage currents can result in the metallic frames becoming live and
energised This can give rise to the danger of electrical shock to the worker consumer or the public if
they hold or come into contact with the metallic frame
ii Exposed Conductor or Disconnected Cable
Exposed conductors or cables which are broken and are alive (energised) can result in electrical shock
when touched The supply source must be immediately isolated or switched off and a report must be
made to the responsible entity
64 First Aid and Basic Pulmonary Resuscitation
i First Aid
First aid is the initial assistance given to a person who has met with an accident is sick or is injured to
prevent the condition of the victim from becoming more serious while awaiting the arrival of the
paramedics (ambulance) or before being brought to the hospital
i Pulmonary Resuscitation
Pulmonary resuscitation has to be undertaken to assist the victim who has breathing difficulties as a
result of being drowned receiving an electrical shock etc Pulmonary resuscitation has to be carried
out in accordance to the correct method as stated in the first aid manuals issued by accredited first aid
bodies
ii First Aid Box
19 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
A first aid box has to be provided by the building owner construction site supervisor or brought
personally by the worker under the supervision of the responsible person
65 Training Programme
The management shall conduct periodic training programmes for the workers with regards to work
safety on aspects including the following -
i Dangers of electrical work being undertaken and how to control those dangers
ii The safety regulations set for the work place and
iii First aid procedures
66 Fire Prevention
Fire Extinguisher A suitable functioning fire extinguisher to control fires has to be made available at
the work place at all times
67 Competent Person
The Electricity Regulations 1994 require that all electrical work has to be undertaken by or under the
direct supervision of a competent person registered with the Energy Commission Besides that the
electrical contractor undertaking the electrical work has also to be registered with the Energy
Commission The installation owner thus has to ensure that the appointed electrical contractor is
registered with the Energy Commission and that the registration is still valid
INSTALLATION CIRCUITS AND SYSTEMS1 Block diagrams
These show using squares rectangles etc the sequence of a system without too much technical detail
eg Figures 1517 and 1526
2 Layout diagrams
These are very similar to block diagrams but they indicate more technical detail and tend to show
items in their correct geographical location (eg Figures 1518 and 1519)
3 Circuitschematic
These show how a circuit functions and takes no account of exact locations of terminals or equipment
(eg Figures 1528 1529 1532 1534 etc)
4 Wiring diagram
These indicate how a circuit or system is physically wired (eg Figures 152 154 156 etc)
Most induction motors are started directly on line but when very large motors are started that way
they cause a disturbance of voltage on the supply lines due to large starting current surges To limit the
starting current surge large induction motors are started at reduced voltage and then have full supply
voltage reconnected when they run up to near rotated speed Two methods are used for reduction of
starting voltage are star delta starting and auto transformer stating
20 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Working Principal of Star-Delta Starter
This is the reduced voltage starting method Voltage reduction during star-delta starting is achieved by
physically reconfiguring the motor windings as illustrated in the figure below During starting the
motor windings are connected in star configuration and this reduces the voltage across each winding 3
This also reduces the torque by a factor of three After a period of time the winding are reconfigured as
delta and the motor runs normally
StarDelta starters are probably the most common reduced voltage starters They are used in
an attempt to reduce the start current applied to the motor during start as a means of reducing the
disturbances and interference on the electrical supply
Traditionally in many supply regions there has been a requirement to fit a reduced voltage
starter on all motors greater than 5HP (4KW) The StarDelta (or WyeDelta) starter is one of the
lowest cost electromechanical reduced voltage starters that can be applied
The StarDelta starter is manufactured from three contactors a timer and a thermal overload
The contactors are smaller than the single contactor used in a Direct on Line starter as they are
controlling winding currents only The currents through the winding are 1root 3 (58) of the
current in the line
There are two contactors that are close during run often referred to as the main contractor and
the delta contactor These are AC3 rated at 58 of the current rating of the motor The third
contactor is the star contactor and that only carries star current while the motor is connected in star
The current in star is one third of the current in delta so this contactor can be AC3 rated at one
third (33) of the motor rating
Star-delta Starter Consists following units
1) Contactors (Main star and delta contactors) 3 Norsquos (For Open State Starter) or 4 Norsquos (Close
Transient Starter)
2) Time relay (pull-in delayed) 1 No
3) Three-pole thermal over current release 1No
4) Fuse elements or automatic cut-outs for the main circuit 3 Nos
5) Fuse element or automatic cut-out for the control circuit 1No
Power Circuit of Star Delta Starter
1 The main circuit breaker serves as the main power supply switch that supplies electricity to the
power circuit
2 The main contactor connects the reference source voltage R Y B to the primary terminal of the
motor U1 V1 W1
21 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
3 In operation the Main Contactor (KM3) and the Star Contactor (KM1) are closed initially and
then after a period of time the star contactor is opened and then the delta contactor (KM2) is
closed The control of the contactors is by the timer (K1T) built into the starter The Star and Delta
are electrically interlocked and preferably mechanically interlocked as well In effect there are
four states
4 The star contactor serves to initially short the secondary terminal of the motor U2 V2 W2 for the
start sequence during the initial run of the motor from standstill This provides one third of DOL
current to the motor thus reducing the high inrush current inherent with large capacity motors at
startup
5 Controlling the interchanging star connection and delta connection of an AC induction motor is
achieved by means of a star delta or wye delta control circuit The control circuit consists of push
button switches auxiliary contacts and a timer
Control Circuit of Star-Delta Starter (Open Transition)
1 The ON push button starts the circuit by initially energizing Star Contactor Coil (KM1) of star
circuit and Timer Coil (KT) circuit
2 When Star Contactor Coil (KM1) energized Star Main and Auxiliary contactor change its
position from NO to NC
3 When Star Auxiliary Contactor (1)( which is placed on Main Contactor coil circuit )became
NO to NC itrsquos complete The Circuit of Main contactor Coil (KM3) so Main Contactor Coil
energized and Main Contactorrsquos Main and Auxiliary Contactor Change its Position from NO
To NC This sequence happens in a friction of time
4 After pushing the ON push button switch the auxiliary contact of the main contactor coil (2)
which is connected in parallel across the ON push button will become NO to NC thereby
providing a latch to hold the main contactor coil activated which eventually maintains the
control circuit active even after releasing the ON push button switch
5 When Star Main Contactor (KM1) close its connect Motor connects on STAR and itrsquos
connected in STAR until Time Delay Auxiliary contact KT (3) become NC to NO
6 Once the time delay is reached its specified Time the timerrsquos auxiliary contacts (KT)(3) in
Star Coil circuit will change its position from NC to NO and at the Same Time Auxiliary
contactor (KT) in Delta Coil Circuit(4) change its Position from NO To NC so Delta coil
energized and Delta Main Contactor becomes NO To NC Now Motor terminal connection
change from star to delta connection
7 A normally close auxiliary contact from both star and delta contactors (5amp6)are also placed
opposite of both star and delta contactor coils these interlock contacts serves as safety
switches to prevent simultaneous activation of both star and delta contactor coils so that one
22 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
cannot be activated without the other deactivated first Thus the delta contactor coil cannot be
active when the star contactor coil is active and similarly the star contactor coil cannot also
be active while the delta contactor coil is active
8 The control circuit above also provides two interrupting contacts to shutdown the motor
The OFF push button switch break the control circuit and the motor when necessary The
thermal overload contact is a protective device which automatically opens the STOP Control
circuit in case when motor overload current is detected by the thermal overload relay this is to
prevent burning of the motor in case of excessive load beyond the rated capacity of the motor
is detected by the thermal overload relay
9 At some point during starting it is necessary to change from a star connected winding to a
delta connected winding Power and control circuits can be arranged to this in one of two
ways ndash open transition or closed transition
What is Open or Closed Transition Starting
(1) Open Transition Starters
Discuss mention above is called open transition switching because there is an open state between
the star state and the delta state
In open transition the power is disconnected from the motor while the winding are reconfigured via
external switching
When a motor is driven by the supply either at full speed or at part speed there is a rotating
magnetic field in the stator This field is rotating at line frequency The flux from the stator field
induces a current in the rotor and this in turn results in a rotor magnetic field
When the motor is disconnected from the supply (open transition) there is a spinning rotor within
the stator and the rotor has a magnetic field Due to the low impedance of the rotor circuit the time
constant is quite long and the action of the spinning rotor field within the stator is that of a
generator which generates voltage at a frequency determined by the speed of the rotor When the
motor is reconnected to the supply it is reclosing onto an unsynchronized generator and this result
in a very high current and torque transient The magnitude of the transient is dependent on the
phase relationship between the generated voltage and the line voltage at the point of closure can
be much higher than DOL current and torque and can result in electrical and mechanical damage
Open transition starting is the easiest to implement in terms or cost and circuitry and if the timing
of the changeover is good this method can work well In practice though it is difficult to set the
necessary timing to operate correctly and disconnectionreconnection of the supply can cause
significant voltagecurrent transients
In Open transition there are Four states
23 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 OFF State All Contactors are open
2 Star State The Main [KM3] and the Star [KM1] contactors are closed and the delta [KM2]
contactor is open The motor is connected in star and will produce one third of DOL torque at one
third of DOL current
3 Open State This type of operation is called open transition switching because there is an
open state between the star state and the delta state The Main contractor is closed and the Delta
and Star contactors are open There is voltage on one end of the motor windings but the other end
is open so no current can flow The motor has a spinning rotor and behaves like a generator
4 Delta State The Main and the Delta contactors are closed The Star contactor is open The
motor is connected to full line voltage and full power and torque are available
(2) Closed Transition StarDelta Starter
There is a technique to reduce the magnitude of the switching transients This requires the use of a
fourth contactor and a set of three resistors The resistors must be sized such that considerable
current is able to flow in the motor windings while they are in circuit
The auxiliary contactor and resistors are connected across the delta contactor In operation just
before the star contactor opens the auxiliary contactor closes resulting in current flow via the
resistors into the star connection Once the star contactor opens current is able to flow round
through the motor windings to the supply via the resistors These resistors are then shorted by the
delta contactor If the resistance of the resistors is too high they will not swamp the voltage
generated by the motor and will serve no purpose
In closed transition the power is maintained to the motor at all time This is achieved by
introducing resistors to take up the current flow during the winding changeover A fourth
contractor is required to place the resistor in circuit before opening the star contactor and then
removing the resistors once the delta contactor is closed These resistors need to be sized to carry
the motor current In addition to requiring more switching devices the control circuit is more
complicated due to the need to carry out resistor switching
In Close transition there are Four states
1 OFF State All Contactors are open
2 Star State The Main [KM3] and the Star [KM1] contactors are closed and the delta [KM2]
contactor is open The motor is connected in star and will produce one third of DOL torque at one
third of DOL current
Star Transition State The motor is connected in star and the resistors are connected across the
delta contactor via the aux [KM4] contactor
24 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Closed Transition State The Main [KM3] contactor is closed and the Delta [KM2] and Star
[KM1] contactors are open Current flows through the motor windings and the transition resistors
via KM4
Delta State The Main and the Delta contactors are closed The transition resistors are shorted out
The Star contactor is open The motor is connected to full line voltage and full power and torque
are available
Effect of Transient in Starter (Open Transient starter)
It is Important the pause between star contactor switch off and Delta contactor switch is on correct
This is because Star contactor must be reliably disconnected before Delta contactor is activated It
is also important that the switch over pause is not too long
For 415v Star Connection voltage is effectively reduced to 58 or 240v The equivalent of 33
that is obtained with Direct Online (DOL) starting
If Star connection has sufficient torque to run up to 75 or 80 of full load speed then the motor
can be connected in Delta mode
When connected to Delta configuration the phase voltage increases by a ratio of V3 or 173 The
phase currents increase by the same ratio The line current increases three times its value in star
connection
During transition period of switchover the motor must be free running with little deceleration
While this is happening ldquoCoastingrdquo it may generate a voltage of its own and on connection to the
supply this voltage can randomly add to or subtract from the applied line voltage This is known as
transient current Only lasting a few milliseconds it causes voltage surges and spikes Known as
a changeover transient
Size of each part of Star-Delta starter
(1) Size of Over Load Relay
For a star-delta starter there is a possibility to place the overload protection in two positions in the
line or in the windings
Overload Relay in Line
In the line is the same as just putting the overload before the motor as with a DOL starter
The rating of Overload (In Line) = FLC of Motor
Disadvantage If the overload is set to FLC then it is not protecting the motor while it is in delta
(setting is x1732 too high)
Overload Relay in Winding
25 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
In the windings means that the overload is placed after the point where the wiring to the contactors
are split into main and delta The overload then always measures the current inside the windings
The setting of Overload Relay (In Winding) =058 X FLC (line current)
Disadvantage We must use separate short circuit and overload protections
(2) Size of Main and Delta Contractor
1 There are two contactors that are close during run often referred to as the main contractor and
the delta contactor These are AC3 rated at 58 of the current rating of the motor
Size of Main Contactor= IFL x 058
(3) Size of Star Contractor
The third contactor is the star contactor and that only carries star current while the motor is
connected in star The current in star is 1 radic3= (58) of the current in delta so this contactor can
be AC3 rated at one third (33) of the motor rating
Size of Star Contactor= IFL x 033
Motor Starting Characteristics of Star-Delta Starter
Available starting current 33 Full Load Current
Peak starting current 13 to 26 Full Load Current
Peak starting torque 33 Full Load Torque
Advantages of Star-Delta starter
The operation of the star-delta method is simple and rugged
It is relatively cheap compared to other reduced voltage methods
Good TorqueCurrent Performance
It draws 2 times starting current of the full load ampere of the motor connected
Disadvantages of Star-Delta starter
Low Starting Torque (Torque = (Square of Voltage) is also reduce)
Break In Supply ndash Possible Transients
Six Terminal Motor Required (Delta Connected)
It requires 2 set of cables from starter to motor
It provides only 33 starting torque and if the load connected to the subject motor requires higher
starting torque at the time of starting than very heavy transients and stresses are produced while
changing from star to delta connections and because of these transients and stresses many
electrical and mechanical break-down occurs
26 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
In this method of starting initially motor is connected in star and then after change over the motor
is connected in delta The delta of motor is formed in starter and not on motor terminals
High transmission and current peaks When starting up pumps and fans for example the load
torque is low at the beginning of the start and increases with the square of the speed When
reaching approx 80-85 of the motor rated speed the load torque is equal to the motor torque and
the acceleration ceases To reach the rated speed a switch over to delta position is necessary and
this will very often result in high transmission and current peaks In some cases the current peak
can reach a value that is even bigger than for a DOL start
Applications with a load torque higher than 50 of the motor rated torque will not be able to start
using the start-delta starter
Low Starting Torque The star-delta (wye-delta) starting method controls whether the lead
connections from the motor are configured in a star or delta electrical connection The initial
connection should be in the star pattern that results in a reduction of the line voltage by a factor of
1radic3 (577) to the motor and the current is reduced to 13 of the current at full voltage but the
starting torque is also reduced 13 to 15 of the DOL starting torque
The transition from star to delta transition usually occurs once nominal speed is reached but is
sometimes performed as low as 50 of nominal speed which make transient Sparks
Features of star-delta starting
1 For low- to high-power three-phase motors
2 Reduced starting current
3 Six connection cables
4 Reduced starting torque
5 Current peak on changeover from star to delta
6 Mechanical load on changeover from star to delta
Application of Star-Delta Starter
The star-delta method is usually only applied to low to medium voltage and light starting
Torque motors
The received starting current is about 30 of the starting current during direct on line start and the
starting torque is reduced to about 25 of the torque available at a DOL start This starting
method only works when the application is light loaded during the start If the motor is too heavily
27 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
loaded there will not be enough torque to accelerate the motor up to speed before switching over
to the delta position
LESSON 1 WIRING SYSTEM OF SINGLE PHASE DISTRIBUTION BOARD
Introduction
28 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
29 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
30 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
31 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 2 WIRING SYSTEM OF SINGLE PHASE LIGHTING CIRCUIT Introduction
Objectives
1 Identify component and the specification
2 Wire component according to the schematic diagram
3 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Wiring bay Perforated metal 180 cm x 180 cm 1
2 Cut out fuse 63 A 240 V 1
3 Neutral link 1
4 Single pole one way switch cw
switch box
5A 240Vac 4
5 single pole two way switch cw
switch box
5A 240Vac 2
6 RCCB In = 40 A Tripping current
100mA240 Vac 50 Hz
1
7 Main switch 32 A 240V 1
8 kWatthour meter 40 A 240 Vac 1
9 Single pole MCB 6A 240 Vac 1
10 Self tapping Wood screw As required
11 DIN rail 35 mm width As required
32 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
12 PVC trunking 50 mm x 50 mm As required
13 Terminal blocks 5 A As required
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
1 One way switch to control one lamp
2 One way switch to control two lamps
3 Two of two way switch to control one lamp
4 Two of single pole two way switch and one of an intermediate switch to control one
lamp
5 One unit of ceiling fan and fan regulator to be controlled by one way switch
4 Test the functionality of completed project
LESSON 3ndash WIRING SYSTEM OF SINGLE PHASE POWER CIRCUIT Introduction
33 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
34 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify types of component and its specification
2 Wire component according to the schematic diagram given
3 Test the functionality of the circuit dead circuit test life circuit test
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board Perforated Metal 1
2 kWh meter 240 V 40 A 1
3 Socket outlet 13A 240Vac 4
4 RCCB 40A Trip Amps
30mA240 Vac
1
5 3 pin socket 240Vac 13A 4
6 Single pole MCB 20A 240 V 2
7 DOL starter 1 kW 240Vac 2
8 1 phase induction motor 2Hp 240 Vac 1
9 Cooker control unit 4kW 240Vac 1
10 Water heater point 4kW 240 Vac 1
11 DIN rail 35 mm As required
12 PVC casing 20mm As required
13 Flexible wires 05 mm As required
14 Terminal block 10 A As required
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Wire two unit of 13 A socket outlet in radial circuit
3 Wire four units of 13 A socket outlet in ring circuit
4 Wire one unit DOL starter for air-conditioner point
5 Wire one unit of cooker control unit point
6 Wire one unit of water heater point
7 Test the functionality of each component by using mmeter or power supply whichever
applicable
8 Wire component according to circuit diagram
9 Test the functionality of completed project dead circuit test life circuit test
Note
35 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Ensure that the correct rating of protection device and size of wire used
LESSON 4ndash CONDUIT BENDING AND TRUNKING FABRICATION TECHNIQUE
Common fitting used in an industrial wiring
Cutting and threading the condute
36 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
37 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
38 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify conduit fitting and the specification
2 Measure and Cut steel conduit according to specified dimension
3 Bend and fabricate conduit at 45 90 according to layout diagram
4 Wire component according to the schematic diagram
5 Test the functionality of the circuit
39 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Conduit Bender Oslash 19 mm ( frac34 ldquo) 1
2 Measuring Tape 3 metre 1
3 Hacksaw frame and blade 30cm 1
4 Conduit cutter 1
5 Pipe Vise 1
6 Pipe Wrench 1
7 Ratchet Dies 20 mm 1
8 Metal trunking 50 mm x 50 mm 1
9 GI conduit 20mm 1
10 End box 20 mm 1
11 Flexible wires 05 mm As required
12 Connectors 5 A As required
13 Single core PVC ins Cable 25 mm 2 As required
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Wire two unit of 13 A socket outlet in radial circuit
3 Wire four unit of 13 A socket outlet in ring circuit
4 Wire one unit DOL starter for air-conditioner point
5 Wire one unit of cooker control unit point
6 Wire one unit of water heater point
7 Test the functionality of each component by using multimeter or power supply whichever
applicable
8 Wire component according to circuit diagram
9 Test the functionality of completed project
Note
Ensure that the rating of protection device and size of wire
K prior to 31 March
2004 (BS 7671)
(formerly)
bare conductor
sleeved at terminations (formerly)
40 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 5 ndashWIRING SYSTEM OF 1 Oslash LIGHTING AND POWER CIRCUIT
POWER CIRCUITSa Radial circuits
Radial circuits are arranged in the same way as item 1 above in lighting layouts in that each socket
outlet is supplied via the previous one
Points to note
1 The number of socket outlets complying with BS 1363 is unlimited for a floor area of up to 50m 2 if
the circuit protection is a 30 A or 32 A cartridge fuse or circuit breaker the cable being 4 mm PVC
copper or 25 mm2 mineral insulated (mi)
2 The number of socket outlets is unlimited for a floor area up to 20 m 2 with any type of circuit
protection of 20 A using 25 mm2 PVC copper cable or 15 mm2 mi
3 The total number of fused spurs is unlimited
b ring final circuits
These circuits are the same as radial circuits except that the final socket outlet is wired back to the
supply position In effect any outlet is supplied from two directions (Fig 152)
Points to note
1 Every twin-socket outlet counts as two single-socket outlets
2 The number of non-fused spurs must not exceed the total number of points on the ring Fig 158
shows seven points on the ring and five spurs
3 The fuse rating of a fused spur box must not exceed 13 A and the current rating of all points supplied
by the fused spur must not exceed 13 A
4 Non-fused spurs must supply no more than one single or one double socket on the ring Fig 158
shows seven points on the ring and five spurs rating of all points supplied by the fused spur must not
exceed 13 A or one stationary appliance
CapacityMain conductor size
copper (mm2)
Earth conductor
size (mm2)
Circuit breaker
capacity (A)
Up to 600 W 15 15 6
600ndash1200 W 1525 15 10
1200ndash1800 W 254 25 16
41 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Ring circuit
(floor area 100 m2)25 15 3032
A2 radial circuit
(floor area 75 m2)40 25 3032
A3 radial circuit
(floor area 50 m2)25 15 20
Air conditioner (15 tonne) 60 60 3032
Cooker 60 60 3032
Water heater 40 40 20
Objectives
1 Identify component and the specification
2 Wire component according to the schematic diagram
3 Test the functionality of the circuit
42 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board Perforated 1
2 Cut out fuse and neutral link 60A 240V 1each
3 kWh meter 240V 40A 1
4 Switched Socket outlet 13A 240Vac 4
5 Single pole two way switch cw switch
box
5A 240Vac 2
6 RCCB ELCB 63 A Tripping current 100mA
415 Vac
1
7 3 pin plug 240Vac 13A 4
8 Single pole MCB 20 A 2
9 Single pole MCB 6A 1
10 Single pole MCB 20A 2
11 DOL starter 240Vac 2
12 1 phase induction motor 2hp 240 Vac 1
13 Self tapping Wood screw As required
14 DIN rail Stainless steel allum35 mm As required
15 PVC pipe 20mm dia As required
16 End box 20 mm dia 4
17 Flexible wires 05 mm 2 As required
18 Connectors 5 A As required
Procedures
43 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
4 Test the functionality of completed project
LESSON 6 ndash WIRING SYSTEM OF 3 Oslash DISTRIBUTION BOARD
Introduction
44 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
45 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
46 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
47 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
48 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify each component and the specification
2 Wire component according to the schematic diagram given
3 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting Board 450 x 600 mm Perforated metal 1
2 5 pin round socket and plug 415V ac 32A 1
3 Cut out fuse 60 A 3
4 Neutral link 1
5 kWatt hour meter 415V 60A 1
6 ELCB RCCB 3P+N In=63A415 Vac I trip= 300mA 1
7 ELCB RCCB 3P+N In=63A415 Vac I trip= 30mA 1
8 Single pole MCB 6A 240 V 3
9 Single pole MCB 20A 240 V 3
10 DOL starter 20 A 240Vac 2
11 Socket outlet 15 A 240 Vac 1
12 Switched Socket outlet 13 A 240 Vac 3
13 Led indicating light 5A 240 Vac 3
14 Single pole 4 gang 1 way switch 5A 240 Vac 2
15 Single pole 2 way switch 5A 240 Vac 2
16 1 phase induction motor 1 kW 240Vac 1
17 Metal trunking 30 mm x30 mm As required
18 Self tapping Wood screw 4 mm x 20 mm As required
19 DIN rail 25 mm x 1mm
20 GI steel rigid conduit 20mm As required
21 Flexible conduit 20mm As required
22 End box 20 mm 4
23 Flexible wires 05 mm 2 As required
24 Single core PVC insulated wire 15 mm 2 As required
25 Single core PVC insulated wires 25 mm 2 As required
26 Terminal block 10 A As required
Procedures
49 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify each components and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
4 Test the functionality of completed project
1 dead circuit test
2 life circuit
Note Proper earthing should be made
50 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 7 ndash WIRING SYSTEM OF THREE PHASE LIGHTING AND POWER CIRCUIT
51 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
52 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify component and the specification
2 Wire component according to the schematic diagram
3 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting bay Board Perforated metal 180 cm x 180 cm 1
2 k Watt hour meter 415V 60A 1
3 MCCB 415V 60A
4 ELCB RCCB In=60A415 Vac I trip=30mA 1
5 5 pin round Socket and
plug
415Vac 32A 4
6 Single pole MCB 6A 1
7 Triple pole MCB 20A 2
8 Triple pole Main switch 60A 1
9 DOL starter 240Vac 2
10 3 phase induction motor 2hp 415 Vac 1
11 1 phase induction motor 1
12 Metal trunking 30 mm x30 mm As required
13 Self tapping Wood screw 4 mm x 20 mm As required
14 DIN rail 25 mm x 1mm
15 GI steel rigid conduit 20mm As required
16 Flexible conduit 20mm As required
17 End box 20 mm 4
18 Flexible wires 05 mm As required
19 Connectors 10 A As required
Procedures
1 Identify each components and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
4 Test the functionality of completed project
1 dead circuit 2 life circuit test
5 Record the current drawn by the load as connected in star and delta
Note Proper earthing should be made
53 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 8 INSPECTION AND TESTING OF ELECTRICAL INSTALLATION
On completion of a wiring installation a number of tests on the installation have to be conducted to
ascertain that the wiring circuits and connected appliances are safe for use Prior to carrying out the
tests an inspection has to be done The results of the inspectionsupervision and test have to be
presented in Form G (as in Appendix IV) and Form H (as in Appendix V)
To have the test certification as in Form H the following tests shall be conducted
i Continuity Test
ii Insulation Resistance Test
iii Polarity Test
iv Earth Electrode Resistance test and
v Residual Current Device Test
1 Continuity Test
There are 3 main types of continuity tests for the final circuits-
i Protection Conductor Continuity Test
ii Final Ring Circuit Conductor Continuity Test
iii Live and Neutral Conductor Continuity Test
a) Protection Conductor Continuity Test
bull To ascertain that all protection conductors are connected in the correct and effective manner
bull Test equipment ndash Multimeter (Ohm range) or Ohm meter
54 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
bull Test Method
1 1048766 Ensure that the main switch RCD and MCB are open circuited (switched off) and all loads
are disconnected
2 1048766 Connected the test leads as in the Figure 81 The meter reading shall be less than 1 Ω
55 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Final Ring Circuit Conductor Continuity Test
bull To ensure that all conductors around the ring circuit have continuity
bull Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
bull Test Method
1 1048766 Disconnect both the supply source live conductors from the MCB the neutral conductor
from the neutral terminals and the earth conductor from the earth terminal in the distribution
fuse box
2 1048766 Connect the test leads as in the Figure 82 (EE)
3 1048766 Repeat the procedure for (L-L) and (N-N)
4 1048766 The meter reading value shall be less than 1 ohm
56 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Live and Neutral Conductor Continuity Test
a To ensure that each conductor in the circuit has continuity
b Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
2 Test Method
1 1048766 Switch off the Main switch RCD and MCB
2 1048766 Disconnect all loads
3 1048766 Switch on all switches in the circuit
4 1048766 Disconnect the fusesfinal circuit breakers and close the circuit
5 1048766 Carry out the test as shown in Figure 83
6 1048766 The meter reading value shall be less than 1Ω
57 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
58 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
CONTINUITY TEST
Insulation Resistance Test
i Ensure that there is no leakage current between phase conductors phase and neutral conductors and
phase conductor and earth
ii Test the strength of the cable insulation
iii Test Equipment ndash Insulation Resistance Tester operating voltage is 250VDC or 500VDC
iv Test Method
1 1048766 Switch off main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
59 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
4 1048766 Carry out test as in the Table below
5 1048766 Meter reading value shall be less than 1 Megaohm
60 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
61 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Insulation resitance test
62 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
INSULATION RESISTANCE TEST BETWEEN CONDUCTORS AND OPPOSITE POLARITY
Polarity Testi Ensure that each fuse or single pole control and protection device is connected only in the phase
conductor
ii Intermediate contact of Edison screw lamp holder is connected to the phase conductor
iii Ensure that phase neutral and earth conductors at socket outlets are connected at the correct
terminals
iv Test Equipment ndash Multimeter (Ohm range) or Ohm meter
v Test Method
1 1048766 Switch off Main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in Figure 85
63 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
5 1048766 Test switches and single phase control devices at the phase conductors
6 1048766 Test socket outlet connection sources
7 1048766 Test Edison screw lamp holder connections
8 1048766 Meter reading value shall be less than 1 Ω
64 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Polarity test
65 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Earth Electrode Resistance Testi To test the earth electrode resistance
ii To ascertain the suitability of the location of the electrode
iii To ensure that the electrode is not buried within the resistance area of another electrode
iv Test equipment ndash Earth Resistance Tester
v Test method -
1 1048766 Terminal rsquoErsquo is connected to the electrode to be tested (green conductor)
2 1048766 Terminal lsquoPrsquo is connected to the potential spike (yellow conductor) at a distance of 10
meters from the earth electrode
3 1048766 Terminal lsquoCrsquo is connected to the current spike (red conductor) at a distance of 20 meters
from the earth electrode
Earth Electrode Resistance Measurement Method (Figure 86)
This test must be repeated at least three times to ensure that the reading is not affected by interacting
earthing regions
i Record the first reading (Z1) Example Z1 = 10 Ω
ii Move the voltage spike to a distance of 6 meters from the original position Record the second
reading (Z2 ) Example Z2 = 10 Ω
iii Move the voltage spike to a distance of 6 meters from the original position Record the third
reading (Z3) Example Z3 = 10 Ω
66 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Residual Current Device Testi Ensure that the residual current device (RCD) trips within the set time on the occurrence of current
leakage to earth
ii Test Equipment ndash RCD Tester RCCB Tester
iii Test Method 1
1 1048766 Use the Trip Test Button
2 1048766 Press the trip button found on the RCD to determine if it trips or otherwise This test would
not be able to determine the sensitivity of the RCD nor the time taken for it to trip
iv Test Method 2
i 1048766 Use a RCD Tester
ii This equipment is equipped with a 13A plug which can be connected to a 13A socket outlet
Select the RCD sensitivity to be the same as the sensitivity of the RCD to be tested to
determine if the RCD can trip The time to trip shall not exceed 40 mS
iii 1048766 Test method ndash
a) Position the selection switch in accordance with the sensitivity of the RCD used
Example 100 mA 01 A
b) Position the operations switch to lsquoNo Triprsquo (frac12 Rated mA = 50) connect the 3 pin plug to
the 13A socket outlet
67 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
c) Switch on the 13A socket outlet ndash ensure that the P-N and P-E lights light up
This shows that the polarity is correct (Note if both the lights as above do not light up the test cannot
be continued)
d) Press the test button ndash the reading shows less than 200 mS and simultaneously the lsquotestrsquo light lights
up and the P-N and P-E lights do not light up At that instant the RCD will not trip
e) Move the selection switch to 180o (+ve wave) ndash repeat steps (d) and (e) Move the operations
switch to lsquoTriprsquo (Rated mA = 100)
g) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200mS
h) Move the selection switch to 0o (-ve wave)
i) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
j) The above test is repeated until a near correct reading is obtained
k) Record the test results
l) Change the operations switch to lsquoFast Triprsquo and press the test button ndash RCD will trip within a
time not exceeding 40 millisecond
m) Repeat a number of times at 0o or 180o
On completion of a wiring installation a number of tests on the installation have to be conducted to
ascertain that the wiring circuits and connected appliances are safe for use Prior to carrying out the
tests an inspection has to be done the following tests shall be conducted
i Continuity Test
ii Insulation Resistance Test
iii Polarity Test
iv Earth Electrode Resistance test and
v Residual Current Device Test
821 Continuity Test
There are 3 main types of continuity tests for the final circuits-
i Protection Conductor Continuity Test
ii Final Ring Circuit Conductor Continuity Test
68 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
iii Live and Neutral Conductor Continuity Test
a) Protection Conductor Continuity Test
bull To ascertain that all protection conductors are connected in the correct and effective manner
bull Test equipment ndash Multimeter (Ohm range) or Ohm meter
bull Test Method
1 1048766 Ensure that the main switch RCD and MCB are open circuited (switched off) and all loads are
disconnected
2 1048766 Connected the test leads as in the Figure 81
3 1048766 The meter reading shall be less than 1 Ω
Final Ring Circuit Conductor Continuity Test
bull To ensure that all conductors around the ring circuit have continuity
bull Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
bull Test Method
1 1048766 Disconnect both the supply source live conductors from the MCB the neutral conductor
from the neutral terminals and the earth conductor from the earth terminal in the distribution
fuse box
2 1048766 Connect the test leads as in the Figure 82 (EE)
3 1048766 Repeat the procedure for (L-L) and (N-N)
4 1048766 The meter reading value shall be less than 1 ohm Figure 82 - Final Ring Circuit Conductor
Continuity Test Ohm Meter
Disconnect both the supply source cables from mcbfuse
Take readings at earth conductors of both sources and note resistance readings
Live and Neutral Conductor Continuity Test
1 To ensure that each conductor in the circuit has continuity
2 Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
3 Test Method
1 1048766 Switch off the Main switch RCD and MCB
2 1048766 Disconnect all loads
3 1048766 Switch on all switches in the circuit
4 1048766 Disconnect the fusesfinal circuit breakers and close the circuit
5 1048766 Carry out the test as shown in Figure 83
6 1048766 The meter reading value shall be less than 1 ohm Figure 83 - Live and Neutral
Conductor Continuity Test Ohm Meter
Insulation Resistance Test
69 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
i Ensure that there is no leakage current between phase conductors phase and neutral conductors and
phase conductor and earth
ii Test the strength of the cable insulation
iii Test Equipment ndash Insulation Resistance Tester Operating voltage is 250VDC or 500VDC
iv Test Method
1 1048766 Switch off main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in the Table below
5 1048766 Meter reading value shall be less than 1 Megaohm
Polarity Test
i Ensure that each fuse or single pole control and protection device is connected only in the phase
conductor
ii Intermediate contact of Edison screw lamp holder is connected to the phase conductor
iii Ensure that phase neutral and earth conductors at socket outlets are connected at the correct
terminals
iv Test Equipment ndash Multimeter (Ohm range) or Ohm meter
v Test Method
1 1048766 Switch off Main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in Figure 85
5 1048766 Test switches and single phase control devices at the phase conductors
6 1048766 Test socket outlet connection sources
7 1048766 Test Edison screw lamp holder connections
8 1048766 Meter reading value shall be less than 1 Ω
Earth Electrode Resistance Test
i To test the earth electrode resistance
70 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
ii To ascertain the suitability of the location of the electrode
iii To ensure that the electrode is not buried within the resistance area of another electrode
iv Test equipment ndash Earth Resistance Tester
v Test method -
1 1048766 Terminal rsquoErsquo is connected to the electrode to be tested (green conductor)
2 1048766 Terminal lsquoPrsquo is connected to the potential spike (yellow conductor) at a distance of 10
meters from the earth electrode
3 1048766 Terminal lsquoCrsquo is connected to the current spike (red conductor) at a distance of 20 meters
from the earth electrode E P C Electrode 10 meter 10 meter
Figure 86 ndash Earth Electrode Resistance Measurement Test Equipment
Earth Electrode Resistance Measurement Method (Figure 86)
This test must be repeated at least three times to ensure that the reading is not affected by interacting
earthing regions
i Record the first reading (Z1) Example Z1 = 10 Ω
ii Move the voltage spike to a distance of 6 meters from the original position Record the second
reading (Z2) Example Z2 = 10 Ω
iii Move the voltage spike to a distance of 6 meters from the original position Record the third
reading (Z3)
Example Z3 = 10 Ω
Residual Current Device Test
71 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
i Ensure that the residual current device (RCD) trips within the set time on the occurrence of current
leakage to earth
ii Test Equipment ndash RCD Tester RCCB Tester
iii Test Method 1
1 1048766 Use the Trip Test Button
2 1048766 Press the trip button found on the RCD to determine if it trips or otherwise This test would
not be able to determine the sensitivity of the RCD nor the time taken for it to trip
iv Test Method 2
1048766 Use a RCD Tester
This equipment is equipped with a 13A plug which can be connected to a 13A socket outlet Select the
RCD sensitivity to be the same as the sensitivity of the RCD to be tested to determine if the RCD can
trip The time to trip shall not exceed 40 mS
1048766 Test method ndash
a) Position the selection switch in accordance with the sensitivity of the RCD used
Example 100 mA 01 A
b) Position the operations switch to lsquoNo Triprsquo (frac12 Rated mA = 50) connect the 3 pin plug to
the 13A socket outlet
c) Switch on the 13A socket outlet ndash ensure that the P-N and P-E lights light up This shows that
the polarity is correct (Note if both the lights as above do not light up the test cannot be
continued)
d) Press the test button ndash the reading shows less than 200 millisecond and simultaneously the
lsquotestrsquo light lights up and the P-N and P-E lights do not light up At that instant the RCD will
not trip
e) Move the selection switch to 180o (+ve wave) ndash repeat steps (d) and (e) = 100)
f) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
g) Move the selection switch to 0o (-ve wave)
h) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
i) The above test is repeated until a near correct reading is obtained
j) Record the test results
k) Change the operations switch to lsquoFast Triprsquo and press the test button ndash RCD will trip within a
time not exceeding 40 mS
l) Repeat a number of times at 0o or 180o
72 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 9 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (DC)
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
73 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Start stop button 240Vac 5A 2
9 Filament lamp (Bulb ) 240Vac 40W 3
10 Overload Relay 415V 20A 3
11 Three phase induction motor 5 hp 3
12 Single phase step down transformer 2500VA 1
13 Single core PVC insulated Cable 1mm 2 As required
14 Single core PVC insulated Cable 25mm 2 As required
15 DIN rail 35 mm As required
16 PVC type Cable tray 50 mm x 50 mm As required
17 Cable ties 4 ldquo As required
18 Flexible wires 05 mm As required
19 PVC Connectors 5 A amp 20 A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the schematic
diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a optional exercise
i Simple DOL starter
ii Forward reverse DOL starter
iii Forward Reverse Dahlander motor
iv Three motors operated in sequence by DOL starter operated by manual push
button or time delay relay
74 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
a One loop per-cycle
b Continuous operation in a loop
c optional circuit design to represent the same task
v Only one out of three motors to be operated at a time (quiz)
4 Test the functionality of completed project
LESSON 10 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (AC)
75 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 1
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Lamp point 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
76 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
11 Overload Relay 415V 20A 3
12 Three phase induction
motor
5 hp 3
13 Single core PVC insulated
Cable
1mm 2 As required
14 Single core PVC insulated
Cable
25mm 2 As required
15 DIN rail 35 mm As required
16 PVC type Cable tray 50 mm x 50 mm As required
17 Cable ties 4 ldquo As required
18 Flexible wires 05 mm As required
19 PVC Connectors 5 A amp 20 A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the
schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram optional exercise
4 Simple DOL starter
5 Forward reverse DOL starter
6 Test the functionality of completed project
77 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 1
78 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
cm
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Indicating light 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
11 Overload Relay 415V 20A 3
12 Three phase induction motor 5 hp 3
13 Single phase step down
transformer
2500VA 1
14 Single core PVC insulated
Cable
1mm 2 As required
15 Single core PVC insulated
Cable
25mm 2 As required
16 DIN rail 35 mm As required
17 PVC type Cable tray 50 mm x 50 mm As required
18 Cable ties 4 ldquo As required
19 Flexible wires 05 mm As required
20 PVC Connectors 5 A amp 20 A 240 V As required
21 Single pole MCB 6A 240 V 1
22 Single pole MCB 2A 240 V 1
23 Triple pole MCB 20A 415 V 1
24 Mounting board 30 cm x 40 cm x 3
cm
1
25 Relay cw 11 pin socket 10 A 240 Vac 2
26 Time delay relay 10 A 240 Vac 3
27 Triple pole Contactor 20A 240Vac 3
28 Batten type Lamp holder 240Vac 10 A 3
29 Start stop button 240Vac 10A 2
30 Indicating light (Bulb ) 240Vac 25W 3
31 Overload Relay 415V 20A 1
32 Three phase dahlander type
induction motor
5 hp 1
33 Single phase step down
transformer
24024Vac
2500VA
1
79 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
34 Single core PVC insulated
Cable
1mm 2 As required
35 Single core PVC insulated
Cable
25mm 2 As required
36 DIN rail 35 mm As required
37 PVC type Cable tray 50 mm x 50 mm As required
38 Cable ties 4 ldquo As required
39 Flexible wires 075 mm As required
40 PVC Connectors 5 A amp 20 A 240 V As required
41 Terminal block 20A 240Vac As required
Procedures
5 Identify each component according to specification and quantity required from the schematic
diagram attached
6 Test the functionality of each component by using multi-meter or power supply whichever
applicable
7 Wire component according to circuit diagram
8 Three motors operated in sequence by DOL starter operated by manual push button or time
delay relay
a One loop per-cycle
b Continuous operation in a loop
c optional circuit design to represent the same task
d Only one out of three motors to be operated at a time (quiz)
9 Test the functionality of completed project
80 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
BASIC DESIGN INDUSTRIAL MOTOR CONTROL (SEQUENCE CONTROL)
THREE PHASE INDUCTION MOTOR OPERATED IN SEQUENCE BY DIRECT ON LINE
STARTER
LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
81 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
82 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Lcd lamp indicator 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
11 Overload Relay 415V 20A 3
12 Three phase induction motor 5 hp 3
13 Single phase step down transformer 2500VA 1
14 Single core PVC insulated Cable 1mm 2 As required
15 Single core PVC insulated Cable 25mm 2 As required
16 DIN rail 35 mm As required
17 PVC type Cable tray 50 mm x 50 mm As required
18 Cable ties 4 ldquo As required
19 Flexible wires 1 mm Oslash As required
20 PVC Terminal block 10A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the schematic
diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a optional exercise
i Forward Reverse dahlander motor
4 Test the functionality of completed project
83 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
THREE PHASE DAHLANDER TYPE INDUCTION MOTOR OPERATED FORWARD AND
REVERSE OPERATION BY DIRECT ON LINE STARTER
84 ndash 99EASYTECH ENTERPRISE
LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
Introduction
If a motors windings are connected in the star configuration any two phases will be in series across
the supply and hence the line current will be smaller(by 577) than if the windings were connected in
the delta arrangement
Hence larger-type motors with heavy starting currents are first connected in star and then when the
starting currents fall in delta This of course means that all six of the ends of the windings must be
brought to terminations outside the casing (Fig 833)
EZTECH
EZTECH ELECTRICAL INSTALLATION GUIDE
The automatic version of this starter incorporates a timing relay which automatically changes the
connections from star to delta Figs 834 and 835 show the wiring and schematic diagrams for a star
delta starter
Objectives
1 Identify component and the specification
2 Design forward reverse star delta starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
2 ndash 99EASYTECH ENTERPRISE
REV -C
LEGENDMCCB Moulded Case Circuit BreakerTOR Thermal Over Load RelayFOW-C Mains Forward ContactorREV-C Mains Reverse ContactorDC Delta ContactorSC Star ContactorS-SW Mains Selector Switch
SC
V2
W2
U2
DC
V1
W1
U1
TOR
TOR
FOW-C
30A MCCB
TOR
MAIN CIRCUIT FORWARD REVERSE STAR DELTA
RYBN S
-SW
3 PHASEINDUCTION MOTOR
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Relay 10 A 240V 3
5 Triple pole Contactor
6 cw NO NC auxiliary contact
240Vac 20 A 4
7 Overload Relay 415 V 1
8 LED indicator 240vac 5 A 4
9 Start stop button 240Vac 5A 2
10 DIN rail 35 mm As required
11 Flexible wires 1 mm As required
12 Single core PVC insulated
wire
25 mm As required
13 Terminal block 20 A As required
14 Squirrel cage motor 5kW 1
15 5 pin plug and socket 415V 20A 1
16 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
3 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
a Manual star delta
b Manual Forward reverse star delta starter
c Automatic star delta starter
d Automatic Forward reverse star delta starter
4 Test the functionality of completed project
4 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
Objectives
1 Identify component and the specification
2 Design auto transformer starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
5 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Autotransformer starter is used to start a 3 phase induction motor that has a rating between 10 to 15 hp
6 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Autotransformer set 10Kw 415 V 50 Hz 1
5 Triple pole Contactor 240Vac 4
6 Batten type Lamp holder 240 Vac 105 A 4
7 Start stop button 240Vac 10A 4
8 Filament lamp (Bulb ) 240Vac 40W 4
9 DIN rail 35 mm As required
10 Flexible wires 1 mm As required
7 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
11 Single core PVC insulated
wire
25 mm As required
12 Terminal block 20 A As required
13 Squirrel cage motor 10kW 1
14 5 pin plug and socket 415V 20A 1
15 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a open transient autotransformer starter
b close transient autotransformer starter
c Forward reverse autotransformer starter
4 Test the functionality of completed project
8 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
Objectives
1 Identify component and the specification
2 Design rotor resistance starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
9 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Rotor Resistor set 10kW 1
5 Triple pole Contactor 240Vac 20A 4
6 Indicating light 240vac 5 A 4
7 Start stop push button 240Vac 5A 4
8 DIN rail 35 mm As required
9 Flexible wires 1 mm 2 As required
10 Single core PVC insulated wire 25 mm 2 As required
11 Terminal block 20 A As required
12 Slip Ring motor 10kW 1
13 5 pin round 3 phase socket 415V 20A 1
14 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
10 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
4 Test the functionality of completed project
a Dead circuit test b Life circuit test
5 Measure starting and running Amps
LESSON 16
TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
An installation in general will suffer damage
Damage usually occurs on the electric motor control as follows
1 Damage to the main circuit
2 Damage to the control circuit
The cause of the damage
i Overcurrent overload short circuit
ii Leakage current to ground
iii Equipment malfunction
iv The main control circuit
a Trip of main circuit protection devices fire
b Defect of motor terminal such as short circuit fire loose
v The control circuit is not functioning -
a contactor relay relay time overload relay does not work damaged burned
b Loose cable connection disconnected
Detecting and Repairing Damage
Examples of damage are as follows
i Motor does not work
ii Motor function and overload relay trips
iii Motor function but only partially functional control circuit
Methods of detecting damage
Among the known methods necessary to detect damage are as follows
1 Turn off the electricity at the main switch (main switch) in order to avoid any danger during the
work carried out to detect damage
2 Check all the protective gear that controls the motor control main circuit
11 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
3 Make sure the damage function control circuit
4 Check the control circuit according to the schematic circuit diagram of the motor control
5 Check the operation of the control circuit
Note
Use wiring that has been installed on the SYSTEM OF MOTOR CONTROL BOARD by Forward
Reverse control circuit for Star Delta to test and look for damage
SELF-ASSESSMENT QUESTIONS
1 (a) Explain what is meant by the term lsquoback emfrsquo in a motor
(b) Outline the basic differences between series shunt and compound wound dc motors
2 (a) With the aid of diagrams explain how the speed of series shunt and compound-wound motors
may be controlled
(b) A 440V dc shunt-wound motor has a field resistance of 200R and an armature resistance of 06 R
When its speed is 20 rev d second the current drawn from the supply is 122A Calculate its back
emf at this speed If the speed were decreased to 19 revssecond the field flux remaining unchanged
calculate the new back emf and the new armature current
3 A load of 64 kW at 240 V is supplied from the terminals of a shunt-wound dc generator The field
resistance is 180 A Calculate the armature current
4 (a) Explain with the aid of a diagram how a rotating magnetic field may be
(b) What is meant by lsquosynchronous speedrsquo
Calculate the synchronous obtained speed of a 12 pole motor if the supply frequency is 50Hz
5 (a) Explain the action of a synchronous motor
(b) What methods are available to start a synchronous motor Explain with diagrams
6 (a) Explain the action of a cage induction motor
(b) What is meant by the term lsquosliprsquo
Calculate the percentage slip of a six pole induction motor running at 162 revssecond from a 50 Hz
supply
7 Describe with sketches three different ways of starting a single-phase induction motor
12 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
8 Explain with the aid of a sketch the action of a three-phase DOL starter
What are dashpots used for How are remote start and stop buttons connected
9 A I0 kW 240V 50Hz single-phase cage rotor induction motor is 85efficient and has a PF of 068
lagging Calculate the motor current and the value of capacitor required to raise the PF to 093
lagging
10 Calculate the torque developed by an 18 kW four-pole induction motor run at 35 slip from a
50Hz supply
APPENDIX 1
13 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 11
14 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 111
Attachment Reference
httpswwwtlc-directcoukBook621htm
httpwwwstgovmyindexphpms
15 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
8 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
21 Selection of Control and Protection System for Electrical Wiring
Control and protection of a wiring is a system of separationisolation and switching together with the
protection system which are needed in every domestic wiring installation
22 Isolation and Switching
Examples of isolation and switching are switches power plugs socket outlets and circuit breakers
Their function is to manually connect and break the supply in a particular circuit without interfering
with other circuits
They also aim to prevent the danger of electrical shocks during maintenance testing fault finding and
repair works
23 Protection
This provides protection from dangers caused by electrical currents such as over current earth
leakage current short circuit lightning etc to the wiring system electrical equipment or consumer
The circuit below shows the isolation and protection devices which must be installed in a domestic
electrical wiring system
1 Current Protection
In general protection from the dangers of current can be divided into two aspects namely
i Overcurrent Protection (Over Load or Short Circuit) Properly rated circuit breakers or fuses suitable
for over load or short circuit protection must be used
9 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
The circuit breakers or fuses must be installed on the live conductors only For three phase circuits all
the circuit breakers or fuses must be combined in one set of circuits
Selection of over current devices must be based on the short circuit fault current levels of the circuit
breaker or main switch (kA)
ii Earth Leakage Current Protection
Properly rated Residual Current Devices (RCD) must be used for protection from earth leakage
currents (to prevent electric shocks)
a) Regulation 36(1) of the Electricity Regulations 1994 states that for a place of public entertainment
protection against earth leakage current must be provided by a residual current device of sensitivity
not exceeding 10 mA
b) Regulation 36(2) of the Electricity Regulations 1994 states that for a place where the floor is likely
to be wet or where the wall or enclosure is of low electrical resistance protection against earth leakage
current must be provided by a residual current device of sensitivity not exceeding 10 mA
c) Regulation 36(3) of the Electricity Regulations 1994 states that for an installation where hand-held
equipment apparatus or appliance is likely to be used protection against earth leakage current must be
provided by a residual current device of sensitivity not exceeding 30 mA and
d) Regulation 36(4) of the Electricity Regulations 1994 states that for an installation other than the
installation in (a) (b) and (c) protection against earth leakage current must be provided by a residual
current device of sensitivity not exceeding 100 mA
CABLE SELECTION
31 Selection of Wiring Cable Type
The selection of the cable size has to take into consideration the following-
i All wiring cables must be PVC or PVCPVC insulated with copper conductors Conductors with
cross sectional areas of 16mm2 or less must be of copper Aluminium conductors are not permitted
Refer to Table 4D1A in Appendix II for the current carrying capacities of copper conductor
ii Cables for swimming pools must be water resistant PE (polyethylene) insulated
10 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
iii The selected cable must be capable of delivering the electrical energy efficiently
iv The cable size allows it to carry the current without heating the cable
v The voltage drop must not exceed 4 of the supply voltage Refer to Table 4D1B in Appendix III
vi The cable insulation must be suitable for the surrounding conditions of the installation such as the
ability to withstand the surrounding temperatures and the ability to provide mechanical protection
vii Each conductor in the installation must be protected from overcurrent by means of overcurrent
protection devices needed to prevent damage to the cable insulation
32 Factors Related to Cable Current Carrying CapacityThe following factors in relation to the current carrying capacity of cables must be taken into
consideration-
i Surface wiring using clips ndash group factor
ii Wiring using conduits ndash space factor 40
iii Wiring using ducts ndash space factor 45
iv Concealed wiring ndash group factor and
v Concealed wiring using ducts ndash surrounding temperature factor
Use of Minimum Cross Sectional Area Rating of Wiring ConductorsThe following are the minimum cross sectional areas of conductors based on their applications-
Use of Protection Conductor Minimum Cross Sectional Area Rating
In Comparison with Phase Conductor Cross Sectional Area
The following table shows the protection conductor minimum cross sectional area in comparison
with the phase conductor cross sectional area
Functions and Colour Identification of Non Flexible Cables
The following table shows the functions and colour identification of non flexible cables
11 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
33 Use of Minimum Cross Sectional Area Rating of Wiring Conductors
The following are the minimum cross sectional areas of conductors based on their applications-
34 Use of Protection Conductor Minimum Cross Sectional Area Rating
In Comparison with Phase Conductor Cross Sectional Area
The following table shows the protection conductor minimum cross sectional area in comparison
with the phase conductor cross sectional area
Use of Minimum Cross Sectional Area Rating of Wiring Conductors
The following are the minimum cross sectional areas of conductors based on their applications-
Use of Protection Conductor Minimum Cross Sectional Area Rating
In Comparison with Phase Conductor Cross Sectional Area
The following table shows the protection conductor minimum cross sectional area in comparison
with the phase conductor cross sectional area
Functions and Colour Identification of Non Flexible CablesThe following table shows the functions and colour identification of non flexible cables
12 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Flexible Cables
i Flexible cables of cross sectional area less than 40 mm2 are used in installations for electrical
accessories such as ceiling roses lamp fixtures or attachments socket plugs for mobile
appliances etc
ii Flexible cables shall not be used for permanent wiring
iii Flexible cables for the permanent use of electrical appliances should not exceed 3 meters in
length
37 Functions and Colour Identification of Flexible Cables
Conductor Insulation and Types of WiringVarious material and insulation layers are used for conductor protection Cable selection in
accordance to insulation layers must be done correctly for the type of the wiring installation as
shown in the table below
Functions and Colour Identification of Non Flexible CablesThe following table shows the functions and colour identification of non flexible cables
3 SELECTION OF WIRING ACCESSORIES
i All wiring accessories to be used have to be of those approved by the Energy Commission and
labeled with labels issued by SIRIM For all wiring using UPVC conduits -
13 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
a) Switches socket outlets 3 pin plugs ceiling roses connectors sockets ndash construction material shall
be of polycarbonate type
iii For all wiring using metal conduits - Switches socket outlets and connectors ndash construction
material shall be of metal clad type and All accessories shall be effectively earthed
iv Switch fuse used in single phase installations shall have the fuse permanently connected and not
move with the fuse
v Fuse switch used in 3 phase domestic installations also has fuse and switch The fuse connector is
installed together to allow the fuse to move simultaneously with the switch
vi Lamp
a) Fluorescent lamps using magnetic ballasts (watt loss not exceeding 6 watts) shall be
equipped with dry paper type capacitor
b) Fluorescent lamps using electronic ballasts or high frequency electronic ballasts do not
need capacitors
c) Outdoor domestic lamp installations shall use weather proof and water proof lamps
d) Submerged light installations (example in swimming pools fountains etc) shall have water
proof lamps with a voltage not exceeding 12 Volt AC
vii Electric water heaters is divided into 2 types namely
1 instantaneous water heaters and
2 stored water heaters (storage tank type)
a) Instantaneous water heaters shall be equipped with a 2 pole control switch and its own
residual current device
b) Storage water heaters (storage tank type) shall be installed with an
Water heaters exceeding 3kW shall be permanently connected to a 20A30A rated circuit
breakerfuse with an isolator switch and residual current device
viii Electric cookers exceeding 3kW shall have its own circuit connected permanently to a 30A rated
circuit breaker or fuse with an isolator switch and cooker control unit incorporated with a 13A socket
outlet Two or more cooker appliances may be installed in the same room within a distance of 2
meters
ix Electric motors (fence gate air conditioners fountains swimming pools fish ponds water
pumps) exceeding 373W but not exceeding 2238W shall be connected permanently to a 20A30A
rated circuit breakerfuse together with an isolator motor starter and 15A socket outlet
14 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
The motor starter shall be of Direct-On-Line type with the appliance together with the contactor
overload relay and on-off control The circuit breakerfuse which controls the motor circuit shall be
capable of withstanding the starting current of the motor
x Electric bells ndash the circuit shall have a push button switch and a ACDC transformer
xi Ceiling fans shall conform to clause 21101 of the MS 12192002 standard with regards to test on
the suspension system of ceiling fans
EARTHING OF ELECTRICAL INSTALLATIONS51 Earthing
Earthing is a connection system between the metallic parts of an electrical wiring system and the
general mass of the earth This will provide an easy path with a low impedence or resistance to earth to
enable the protection system to operate effectively It will thus ensure safety to human
beingsconsumers from the dangers of electric shocks if earth leakage currents are present In general
an electrical installation is earthed because of -
i Safety reasons
ii Protection system requirements
iii Need to limit over voltages
iv Need to provide a path for electrical discharge
v Legal requirements
52 Classification of Earthing
Generally earthing can be divided into 2 parts namely -
i System Earthing
a To isolate the system under fault conditions
b To limit the potential difference between conductors which are not insulated in an area
c To limit the occurrence of over voltages under various conditions
ii Equipment Earthing
Equipment earthing is undertaken to protect human beingsconsumers If a live source comes into
contact with the equipment body electrical energy will flow to the earth without flowing through the
human being consumerrsquos body This is because of the fact that the human body has a greater
resistance compared with the resistance to earth
53 Types and Functions of Earthing Accessories
Earthing accessories are as follows -
i Earthing Electrode
Copper jacketed steel core rods are used as electrodes for domestic wiring
ii Equipotential Bonding
15 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
This is the conductor which is connected between the consumer earthing point and the exposed
metallic part The minimum cable size for this purpose is 10 mm2
iii Protection Conductor
This is the conductor which connects the consumer earthing point with other parts of the installation
which needs earthing Its size is as follows-
a) Same size as the phase cable up to a size of 16mm2
b) 16 mm2 if the phase cable size is between 16 mm2 and 35 mm2
c) Half the size of the phase cable if the size of the phase cable exceeds 35 mm2
54 Earthing Arrangements Using a TT System
i The first alphabet indicates the earthing arrangements from the supply side
ii The second alphabet indicates the earthing arrangement in the consumerrsquos installation
T ndash first Indicates that the supply system has its own earthing arrangements
T ndash second Indicates that all metallic frames of the electrical appliances etc are connected directly to
earth
Parts that are Required to be Earthed
i All metallic structures in the wiring system (non current carrying) such as metallic covers conduits
ducts the armour of catenary wires etc
ii A secondary winding point in a transformer and
iii Frame of metal roof truss
56 Parts that are not Required to be Earthed
i Short isolated metallic parts for mechanical protection of cables which have non metallic sheaths
other than conduits which are connected at entry points between the building and conduits which
protect discharge lamp cables
ii Cable clips for installing cables
iii Metallic covers for lamps
16 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
iv Small metallic parts such as screws and name plates which are isolated by means of insulation
v Metallic lamp parts for filament lamps in water proof floors
57 Termination to Earth
The termination to earth is done as shown in Figure 72
Earth Electrode Resistance
The maximum permitted earth electrode resistance for different types of installations is as shown in
the Table below
Earth electrode for installations protected by RCDs of sensitivity 100mA 10 Ω
Lightning arrestor earth electrode 10 Ω
Legal Requirements
i Sub regulation 12(1) and 12(2) of the Electricity Regulations 1994 state that any electrical wiring in
an installation shall be under the immediate supervision of a Wireman with Single Phase Restriction or
Three Phase Restriction Upon completion the Wireman shall certify a Supervision and Completion
Certificate
ii Sub regulation 13(1) and 13 (2) of the Electricity Regulations 1994 state that the installation shall
be tested by a Wireman with Single Phase Restriction or a Wireman with Three Phase Restriction
authorized to test any installation and who shall certify a Test Certificate for the installation
iii Sub regulation 14(1) of the Electricity Regulations 1994 states that the Supervision and
Completion Certificate and the Test Certificate as in regulations 12 and 13 shall be in Forms G and H
respectively as prescribed in the First Schedule
17 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
4 SAFETY REQUIREMENTS FOR ELECTRICAL WIRING WORKS IN RESIDENTIAL BUILDINGS
61 Safety Requirements
Safety requirements for electrical wiring works have to be followed to eliminate any accidents which
can result in physical damage or loss of life or property Failure to meet the safety regulations may
result in workers consumers or the public being inflicted with electrical shocks
In addition to this safety steps will also encourage workers or electricity consumers who are
disciplined and who always give importance to safety
62 Safety Steps
Safety requirements have to be followed whenever electrical works are undertaken in a residential
building
i Personal Safety
a Use suitable personal protection equipment as needed such as safety shoes gloves safety helmet
etc when at the work place
b Use safety clothing suitable for the work to be undertaken
c Do not wear jewellery or decorative items such as rings watches chains etc while carrying out
electrical works
ii Safety at the Work Place
a Acquire knowledge about the dangers of electrical works that is to be undertaken and how to deal
with those dangers
b Always adhere to the safety regulations which have been set for the work place
c Ensure that the electricity supply is switched off before carrying out the works
d Acquire the needed knowledge and practice a cautious and calm attitude while working ensure
cleanliness in and around fellow workers
e While working at elevated places the worker should always use suitable equipment such as wooden
or aluminium ladders iron scaffoldings or platforms safety belts or other equipment needed to ensure
that the work can be undertaken safely
f Use electrical equipment which is operational and safe to be used and ensure that the supply for it is
being supplied through a residual current device (RCD) with a sensitivity of 30 mA
g Ensure that exposed temporary supply electrical cables have mechanical protection
h If inflammable or corrosive material is present necessary safety steps have to be undertaken as
required by the relevant safety regulations
63 Dangers of Electrical Shocks
i Electrical Shock
Electrical shocks can occur due to direct or indirect contact
a Direct Contact
18 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Direct contact occurs when the worker or consumer receives an electrical shock on touching directly a
live conductor or cable
b Indirect Contact
Here the electric shock occurs due to contact with a part which is connected to the electrical
installation and not to a direct contact with a live cable or conductor possibly due to damages in the
appliance or insulation resulting in leakages of current
Why Electric Shocks Occura Unsafe Work Method or Action Undertaking Electrical Work Without Disconnecting the
Supply
Maintenance or circuit testing work done without disconnecting the supply will have a high possibility
of electrical shocks occurring
bull Not Following Safe Work Procedures
To eliminate the occurrence of electrical shocks each worker has to always follow safe work
procedures which are set by regulations and standards
b Defects in the Electrical System
i Leakage Current
Leakage currents or earth leakage currents can result in the metallic frames becoming live and
energised This can give rise to the danger of electrical shock to the worker consumer or the public if
they hold or come into contact with the metallic frame
ii Exposed Conductor or Disconnected Cable
Exposed conductors or cables which are broken and are alive (energised) can result in electrical shock
when touched The supply source must be immediately isolated or switched off and a report must be
made to the responsible entity
64 First Aid and Basic Pulmonary Resuscitation
i First Aid
First aid is the initial assistance given to a person who has met with an accident is sick or is injured to
prevent the condition of the victim from becoming more serious while awaiting the arrival of the
paramedics (ambulance) or before being brought to the hospital
i Pulmonary Resuscitation
Pulmonary resuscitation has to be undertaken to assist the victim who has breathing difficulties as a
result of being drowned receiving an electrical shock etc Pulmonary resuscitation has to be carried
out in accordance to the correct method as stated in the first aid manuals issued by accredited first aid
bodies
ii First Aid Box
19 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
A first aid box has to be provided by the building owner construction site supervisor or brought
personally by the worker under the supervision of the responsible person
65 Training Programme
The management shall conduct periodic training programmes for the workers with regards to work
safety on aspects including the following -
i Dangers of electrical work being undertaken and how to control those dangers
ii The safety regulations set for the work place and
iii First aid procedures
66 Fire Prevention
Fire Extinguisher A suitable functioning fire extinguisher to control fires has to be made available at
the work place at all times
67 Competent Person
The Electricity Regulations 1994 require that all electrical work has to be undertaken by or under the
direct supervision of a competent person registered with the Energy Commission Besides that the
electrical contractor undertaking the electrical work has also to be registered with the Energy
Commission The installation owner thus has to ensure that the appointed electrical contractor is
registered with the Energy Commission and that the registration is still valid
INSTALLATION CIRCUITS AND SYSTEMS1 Block diagrams
These show using squares rectangles etc the sequence of a system without too much technical detail
eg Figures 1517 and 1526
2 Layout diagrams
These are very similar to block diagrams but they indicate more technical detail and tend to show
items in their correct geographical location (eg Figures 1518 and 1519)
3 Circuitschematic
These show how a circuit functions and takes no account of exact locations of terminals or equipment
(eg Figures 1528 1529 1532 1534 etc)
4 Wiring diagram
These indicate how a circuit or system is physically wired (eg Figures 152 154 156 etc)
Most induction motors are started directly on line but when very large motors are started that way
they cause a disturbance of voltage on the supply lines due to large starting current surges To limit the
starting current surge large induction motors are started at reduced voltage and then have full supply
voltage reconnected when they run up to near rotated speed Two methods are used for reduction of
starting voltage are star delta starting and auto transformer stating
20 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Working Principal of Star-Delta Starter
This is the reduced voltage starting method Voltage reduction during star-delta starting is achieved by
physically reconfiguring the motor windings as illustrated in the figure below During starting the
motor windings are connected in star configuration and this reduces the voltage across each winding 3
This also reduces the torque by a factor of three After a period of time the winding are reconfigured as
delta and the motor runs normally
StarDelta starters are probably the most common reduced voltage starters They are used in
an attempt to reduce the start current applied to the motor during start as a means of reducing the
disturbances and interference on the electrical supply
Traditionally in many supply regions there has been a requirement to fit a reduced voltage
starter on all motors greater than 5HP (4KW) The StarDelta (or WyeDelta) starter is one of the
lowest cost electromechanical reduced voltage starters that can be applied
The StarDelta starter is manufactured from three contactors a timer and a thermal overload
The contactors are smaller than the single contactor used in a Direct on Line starter as they are
controlling winding currents only The currents through the winding are 1root 3 (58) of the
current in the line
There are two contactors that are close during run often referred to as the main contractor and
the delta contactor These are AC3 rated at 58 of the current rating of the motor The third
contactor is the star contactor and that only carries star current while the motor is connected in star
The current in star is one third of the current in delta so this contactor can be AC3 rated at one
third (33) of the motor rating
Star-delta Starter Consists following units
1) Contactors (Main star and delta contactors) 3 Norsquos (For Open State Starter) or 4 Norsquos (Close
Transient Starter)
2) Time relay (pull-in delayed) 1 No
3) Three-pole thermal over current release 1No
4) Fuse elements or automatic cut-outs for the main circuit 3 Nos
5) Fuse element or automatic cut-out for the control circuit 1No
Power Circuit of Star Delta Starter
1 The main circuit breaker serves as the main power supply switch that supplies electricity to the
power circuit
2 The main contactor connects the reference source voltage R Y B to the primary terminal of the
motor U1 V1 W1
21 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
3 In operation the Main Contactor (KM3) and the Star Contactor (KM1) are closed initially and
then after a period of time the star contactor is opened and then the delta contactor (KM2) is
closed The control of the contactors is by the timer (K1T) built into the starter The Star and Delta
are electrically interlocked and preferably mechanically interlocked as well In effect there are
four states
4 The star contactor serves to initially short the secondary terminal of the motor U2 V2 W2 for the
start sequence during the initial run of the motor from standstill This provides one third of DOL
current to the motor thus reducing the high inrush current inherent with large capacity motors at
startup
5 Controlling the interchanging star connection and delta connection of an AC induction motor is
achieved by means of a star delta or wye delta control circuit The control circuit consists of push
button switches auxiliary contacts and a timer
Control Circuit of Star-Delta Starter (Open Transition)
1 The ON push button starts the circuit by initially energizing Star Contactor Coil (KM1) of star
circuit and Timer Coil (KT) circuit
2 When Star Contactor Coil (KM1) energized Star Main and Auxiliary contactor change its
position from NO to NC
3 When Star Auxiliary Contactor (1)( which is placed on Main Contactor coil circuit )became
NO to NC itrsquos complete The Circuit of Main contactor Coil (KM3) so Main Contactor Coil
energized and Main Contactorrsquos Main and Auxiliary Contactor Change its Position from NO
To NC This sequence happens in a friction of time
4 After pushing the ON push button switch the auxiliary contact of the main contactor coil (2)
which is connected in parallel across the ON push button will become NO to NC thereby
providing a latch to hold the main contactor coil activated which eventually maintains the
control circuit active even after releasing the ON push button switch
5 When Star Main Contactor (KM1) close its connect Motor connects on STAR and itrsquos
connected in STAR until Time Delay Auxiliary contact KT (3) become NC to NO
6 Once the time delay is reached its specified Time the timerrsquos auxiliary contacts (KT)(3) in
Star Coil circuit will change its position from NC to NO and at the Same Time Auxiliary
contactor (KT) in Delta Coil Circuit(4) change its Position from NO To NC so Delta coil
energized and Delta Main Contactor becomes NO To NC Now Motor terminal connection
change from star to delta connection
7 A normally close auxiliary contact from both star and delta contactors (5amp6)are also placed
opposite of both star and delta contactor coils these interlock contacts serves as safety
switches to prevent simultaneous activation of both star and delta contactor coils so that one
22 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
cannot be activated without the other deactivated first Thus the delta contactor coil cannot be
active when the star contactor coil is active and similarly the star contactor coil cannot also
be active while the delta contactor coil is active
8 The control circuit above also provides two interrupting contacts to shutdown the motor
The OFF push button switch break the control circuit and the motor when necessary The
thermal overload contact is a protective device which automatically opens the STOP Control
circuit in case when motor overload current is detected by the thermal overload relay this is to
prevent burning of the motor in case of excessive load beyond the rated capacity of the motor
is detected by the thermal overload relay
9 At some point during starting it is necessary to change from a star connected winding to a
delta connected winding Power and control circuits can be arranged to this in one of two
ways ndash open transition or closed transition
What is Open or Closed Transition Starting
(1) Open Transition Starters
Discuss mention above is called open transition switching because there is an open state between
the star state and the delta state
In open transition the power is disconnected from the motor while the winding are reconfigured via
external switching
When a motor is driven by the supply either at full speed or at part speed there is a rotating
magnetic field in the stator This field is rotating at line frequency The flux from the stator field
induces a current in the rotor and this in turn results in a rotor magnetic field
When the motor is disconnected from the supply (open transition) there is a spinning rotor within
the stator and the rotor has a magnetic field Due to the low impedance of the rotor circuit the time
constant is quite long and the action of the spinning rotor field within the stator is that of a
generator which generates voltage at a frequency determined by the speed of the rotor When the
motor is reconnected to the supply it is reclosing onto an unsynchronized generator and this result
in a very high current and torque transient The magnitude of the transient is dependent on the
phase relationship between the generated voltage and the line voltage at the point of closure can
be much higher than DOL current and torque and can result in electrical and mechanical damage
Open transition starting is the easiest to implement in terms or cost and circuitry and if the timing
of the changeover is good this method can work well In practice though it is difficult to set the
necessary timing to operate correctly and disconnectionreconnection of the supply can cause
significant voltagecurrent transients
In Open transition there are Four states
23 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 OFF State All Contactors are open
2 Star State The Main [KM3] and the Star [KM1] contactors are closed and the delta [KM2]
contactor is open The motor is connected in star and will produce one third of DOL torque at one
third of DOL current
3 Open State This type of operation is called open transition switching because there is an
open state between the star state and the delta state The Main contractor is closed and the Delta
and Star contactors are open There is voltage on one end of the motor windings but the other end
is open so no current can flow The motor has a spinning rotor and behaves like a generator
4 Delta State The Main and the Delta contactors are closed The Star contactor is open The
motor is connected to full line voltage and full power and torque are available
(2) Closed Transition StarDelta Starter
There is a technique to reduce the magnitude of the switching transients This requires the use of a
fourth contactor and a set of three resistors The resistors must be sized such that considerable
current is able to flow in the motor windings while they are in circuit
The auxiliary contactor and resistors are connected across the delta contactor In operation just
before the star contactor opens the auxiliary contactor closes resulting in current flow via the
resistors into the star connection Once the star contactor opens current is able to flow round
through the motor windings to the supply via the resistors These resistors are then shorted by the
delta contactor If the resistance of the resistors is too high they will not swamp the voltage
generated by the motor and will serve no purpose
In closed transition the power is maintained to the motor at all time This is achieved by
introducing resistors to take up the current flow during the winding changeover A fourth
contractor is required to place the resistor in circuit before opening the star contactor and then
removing the resistors once the delta contactor is closed These resistors need to be sized to carry
the motor current In addition to requiring more switching devices the control circuit is more
complicated due to the need to carry out resistor switching
In Close transition there are Four states
1 OFF State All Contactors are open
2 Star State The Main [KM3] and the Star [KM1] contactors are closed and the delta [KM2]
contactor is open The motor is connected in star and will produce one third of DOL torque at one
third of DOL current
Star Transition State The motor is connected in star and the resistors are connected across the
delta contactor via the aux [KM4] contactor
24 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Closed Transition State The Main [KM3] contactor is closed and the Delta [KM2] and Star
[KM1] contactors are open Current flows through the motor windings and the transition resistors
via KM4
Delta State The Main and the Delta contactors are closed The transition resistors are shorted out
The Star contactor is open The motor is connected to full line voltage and full power and torque
are available
Effect of Transient in Starter (Open Transient starter)
It is Important the pause between star contactor switch off and Delta contactor switch is on correct
This is because Star contactor must be reliably disconnected before Delta contactor is activated It
is also important that the switch over pause is not too long
For 415v Star Connection voltage is effectively reduced to 58 or 240v The equivalent of 33
that is obtained with Direct Online (DOL) starting
If Star connection has sufficient torque to run up to 75 or 80 of full load speed then the motor
can be connected in Delta mode
When connected to Delta configuration the phase voltage increases by a ratio of V3 or 173 The
phase currents increase by the same ratio The line current increases three times its value in star
connection
During transition period of switchover the motor must be free running with little deceleration
While this is happening ldquoCoastingrdquo it may generate a voltage of its own and on connection to the
supply this voltage can randomly add to or subtract from the applied line voltage This is known as
transient current Only lasting a few milliseconds it causes voltage surges and spikes Known as
a changeover transient
Size of each part of Star-Delta starter
(1) Size of Over Load Relay
For a star-delta starter there is a possibility to place the overload protection in two positions in the
line or in the windings
Overload Relay in Line
In the line is the same as just putting the overload before the motor as with a DOL starter
The rating of Overload (In Line) = FLC of Motor
Disadvantage If the overload is set to FLC then it is not protecting the motor while it is in delta
(setting is x1732 too high)
Overload Relay in Winding
25 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
In the windings means that the overload is placed after the point where the wiring to the contactors
are split into main and delta The overload then always measures the current inside the windings
The setting of Overload Relay (In Winding) =058 X FLC (line current)
Disadvantage We must use separate short circuit and overload protections
(2) Size of Main and Delta Contractor
1 There are two contactors that are close during run often referred to as the main contractor and
the delta contactor These are AC3 rated at 58 of the current rating of the motor
Size of Main Contactor= IFL x 058
(3) Size of Star Contractor
The third contactor is the star contactor and that only carries star current while the motor is
connected in star The current in star is 1 radic3= (58) of the current in delta so this contactor can
be AC3 rated at one third (33) of the motor rating
Size of Star Contactor= IFL x 033
Motor Starting Characteristics of Star-Delta Starter
Available starting current 33 Full Load Current
Peak starting current 13 to 26 Full Load Current
Peak starting torque 33 Full Load Torque
Advantages of Star-Delta starter
The operation of the star-delta method is simple and rugged
It is relatively cheap compared to other reduced voltage methods
Good TorqueCurrent Performance
It draws 2 times starting current of the full load ampere of the motor connected
Disadvantages of Star-Delta starter
Low Starting Torque (Torque = (Square of Voltage) is also reduce)
Break In Supply ndash Possible Transients
Six Terminal Motor Required (Delta Connected)
It requires 2 set of cables from starter to motor
It provides only 33 starting torque and if the load connected to the subject motor requires higher
starting torque at the time of starting than very heavy transients and stresses are produced while
changing from star to delta connections and because of these transients and stresses many
electrical and mechanical break-down occurs
26 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
In this method of starting initially motor is connected in star and then after change over the motor
is connected in delta The delta of motor is formed in starter and not on motor terminals
High transmission and current peaks When starting up pumps and fans for example the load
torque is low at the beginning of the start and increases with the square of the speed When
reaching approx 80-85 of the motor rated speed the load torque is equal to the motor torque and
the acceleration ceases To reach the rated speed a switch over to delta position is necessary and
this will very often result in high transmission and current peaks In some cases the current peak
can reach a value that is even bigger than for a DOL start
Applications with a load torque higher than 50 of the motor rated torque will not be able to start
using the start-delta starter
Low Starting Torque The star-delta (wye-delta) starting method controls whether the lead
connections from the motor are configured in a star or delta electrical connection The initial
connection should be in the star pattern that results in a reduction of the line voltage by a factor of
1radic3 (577) to the motor and the current is reduced to 13 of the current at full voltage but the
starting torque is also reduced 13 to 15 of the DOL starting torque
The transition from star to delta transition usually occurs once nominal speed is reached but is
sometimes performed as low as 50 of nominal speed which make transient Sparks
Features of star-delta starting
1 For low- to high-power three-phase motors
2 Reduced starting current
3 Six connection cables
4 Reduced starting torque
5 Current peak on changeover from star to delta
6 Mechanical load on changeover from star to delta
Application of Star-Delta Starter
The star-delta method is usually only applied to low to medium voltage and light starting
Torque motors
The received starting current is about 30 of the starting current during direct on line start and the
starting torque is reduced to about 25 of the torque available at a DOL start This starting
method only works when the application is light loaded during the start If the motor is too heavily
27 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
loaded there will not be enough torque to accelerate the motor up to speed before switching over
to the delta position
LESSON 1 WIRING SYSTEM OF SINGLE PHASE DISTRIBUTION BOARD
Introduction
28 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
29 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
30 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
31 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 2 WIRING SYSTEM OF SINGLE PHASE LIGHTING CIRCUIT Introduction
Objectives
1 Identify component and the specification
2 Wire component according to the schematic diagram
3 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Wiring bay Perforated metal 180 cm x 180 cm 1
2 Cut out fuse 63 A 240 V 1
3 Neutral link 1
4 Single pole one way switch cw
switch box
5A 240Vac 4
5 single pole two way switch cw
switch box
5A 240Vac 2
6 RCCB In = 40 A Tripping current
100mA240 Vac 50 Hz
1
7 Main switch 32 A 240V 1
8 kWatthour meter 40 A 240 Vac 1
9 Single pole MCB 6A 240 Vac 1
10 Self tapping Wood screw As required
11 DIN rail 35 mm width As required
32 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
12 PVC trunking 50 mm x 50 mm As required
13 Terminal blocks 5 A As required
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
1 One way switch to control one lamp
2 One way switch to control two lamps
3 Two of two way switch to control one lamp
4 Two of single pole two way switch and one of an intermediate switch to control one
lamp
5 One unit of ceiling fan and fan regulator to be controlled by one way switch
4 Test the functionality of completed project
LESSON 3ndash WIRING SYSTEM OF SINGLE PHASE POWER CIRCUIT Introduction
33 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
34 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify types of component and its specification
2 Wire component according to the schematic diagram given
3 Test the functionality of the circuit dead circuit test life circuit test
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board Perforated Metal 1
2 kWh meter 240 V 40 A 1
3 Socket outlet 13A 240Vac 4
4 RCCB 40A Trip Amps
30mA240 Vac
1
5 3 pin socket 240Vac 13A 4
6 Single pole MCB 20A 240 V 2
7 DOL starter 1 kW 240Vac 2
8 1 phase induction motor 2Hp 240 Vac 1
9 Cooker control unit 4kW 240Vac 1
10 Water heater point 4kW 240 Vac 1
11 DIN rail 35 mm As required
12 PVC casing 20mm As required
13 Flexible wires 05 mm As required
14 Terminal block 10 A As required
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Wire two unit of 13 A socket outlet in radial circuit
3 Wire four units of 13 A socket outlet in ring circuit
4 Wire one unit DOL starter for air-conditioner point
5 Wire one unit of cooker control unit point
6 Wire one unit of water heater point
7 Test the functionality of each component by using mmeter or power supply whichever
applicable
8 Wire component according to circuit diagram
9 Test the functionality of completed project dead circuit test life circuit test
Note
35 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Ensure that the correct rating of protection device and size of wire used
LESSON 4ndash CONDUIT BENDING AND TRUNKING FABRICATION TECHNIQUE
Common fitting used in an industrial wiring
Cutting and threading the condute
36 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
37 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
38 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify conduit fitting and the specification
2 Measure and Cut steel conduit according to specified dimension
3 Bend and fabricate conduit at 45 90 according to layout diagram
4 Wire component according to the schematic diagram
5 Test the functionality of the circuit
39 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Conduit Bender Oslash 19 mm ( frac34 ldquo) 1
2 Measuring Tape 3 metre 1
3 Hacksaw frame and blade 30cm 1
4 Conduit cutter 1
5 Pipe Vise 1
6 Pipe Wrench 1
7 Ratchet Dies 20 mm 1
8 Metal trunking 50 mm x 50 mm 1
9 GI conduit 20mm 1
10 End box 20 mm 1
11 Flexible wires 05 mm As required
12 Connectors 5 A As required
13 Single core PVC ins Cable 25 mm 2 As required
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Wire two unit of 13 A socket outlet in radial circuit
3 Wire four unit of 13 A socket outlet in ring circuit
4 Wire one unit DOL starter for air-conditioner point
5 Wire one unit of cooker control unit point
6 Wire one unit of water heater point
7 Test the functionality of each component by using multimeter or power supply whichever
applicable
8 Wire component according to circuit diagram
9 Test the functionality of completed project
Note
Ensure that the rating of protection device and size of wire
K prior to 31 March
2004 (BS 7671)
(formerly)
bare conductor
sleeved at terminations (formerly)
40 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 5 ndashWIRING SYSTEM OF 1 Oslash LIGHTING AND POWER CIRCUIT
POWER CIRCUITSa Radial circuits
Radial circuits are arranged in the same way as item 1 above in lighting layouts in that each socket
outlet is supplied via the previous one
Points to note
1 The number of socket outlets complying with BS 1363 is unlimited for a floor area of up to 50m 2 if
the circuit protection is a 30 A or 32 A cartridge fuse or circuit breaker the cable being 4 mm PVC
copper or 25 mm2 mineral insulated (mi)
2 The number of socket outlets is unlimited for a floor area up to 20 m 2 with any type of circuit
protection of 20 A using 25 mm2 PVC copper cable or 15 mm2 mi
3 The total number of fused spurs is unlimited
b ring final circuits
These circuits are the same as radial circuits except that the final socket outlet is wired back to the
supply position In effect any outlet is supplied from two directions (Fig 152)
Points to note
1 Every twin-socket outlet counts as two single-socket outlets
2 The number of non-fused spurs must not exceed the total number of points on the ring Fig 158
shows seven points on the ring and five spurs
3 The fuse rating of a fused spur box must not exceed 13 A and the current rating of all points supplied
by the fused spur must not exceed 13 A
4 Non-fused spurs must supply no more than one single or one double socket on the ring Fig 158
shows seven points on the ring and five spurs rating of all points supplied by the fused spur must not
exceed 13 A or one stationary appliance
CapacityMain conductor size
copper (mm2)
Earth conductor
size (mm2)
Circuit breaker
capacity (A)
Up to 600 W 15 15 6
600ndash1200 W 1525 15 10
1200ndash1800 W 254 25 16
41 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Ring circuit
(floor area 100 m2)25 15 3032
A2 radial circuit
(floor area 75 m2)40 25 3032
A3 radial circuit
(floor area 50 m2)25 15 20
Air conditioner (15 tonne) 60 60 3032
Cooker 60 60 3032
Water heater 40 40 20
Objectives
1 Identify component and the specification
2 Wire component according to the schematic diagram
3 Test the functionality of the circuit
42 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board Perforated 1
2 Cut out fuse and neutral link 60A 240V 1each
3 kWh meter 240V 40A 1
4 Switched Socket outlet 13A 240Vac 4
5 Single pole two way switch cw switch
box
5A 240Vac 2
6 RCCB ELCB 63 A Tripping current 100mA
415 Vac
1
7 3 pin plug 240Vac 13A 4
8 Single pole MCB 20 A 2
9 Single pole MCB 6A 1
10 Single pole MCB 20A 2
11 DOL starter 240Vac 2
12 1 phase induction motor 2hp 240 Vac 1
13 Self tapping Wood screw As required
14 DIN rail Stainless steel allum35 mm As required
15 PVC pipe 20mm dia As required
16 End box 20 mm dia 4
17 Flexible wires 05 mm 2 As required
18 Connectors 5 A As required
Procedures
43 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
4 Test the functionality of completed project
LESSON 6 ndash WIRING SYSTEM OF 3 Oslash DISTRIBUTION BOARD
Introduction
44 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
45 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
46 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
47 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
48 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify each component and the specification
2 Wire component according to the schematic diagram given
3 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting Board 450 x 600 mm Perforated metal 1
2 5 pin round socket and plug 415V ac 32A 1
3 Cut out fuse 60 A 3
4 Neutral link 1
5 kWatt hour meter 415V 60A 1
6 ELCB RCCB 3P+N In=63A415 Vac I trip= 300mA 1
7 ELCB RCCB 3P+N In=63A415 Vac I trip= 30mA 1
8 Single pole MCB 6A 240 V 3
9 Single pole MCB 20A 240 V 3
10 DOL starter 20 A 240Vac 2
11 Socket outlet 15 A 240 Vac 1
12 Switched Socket outlet 13 A 240 Vac 3
13 Led indicating light 5A 240 Vac 3
14 Single pole 4 gang 1 way switch 5A 240 Vac 2
15 Single pole 2 way switch 5A 240 Vac 2
16 1 phase induction motor 1 kW 240Vac 1
17 Metal trunking 30 mm x30 mm As required
18 Self tapping Wood screw 4 mm x 20 mm As required
19 DIN rail 25 mm x 1mm
20 GI steel rigid conduit 20mm As required
21 Flexible conduit 20mm As required
22 End box 20 mm 4
23 Flexible wires 05 mm 2 As required
24 Single core PVC insulated wire 15 mm 2 As required
25 Single core PVC insulated wires 25 mm 2 As required
26 Terminal block 10 A As required
Procedures
49 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify each components and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
4 Test the functionality of completed project
1 dead circuit test
2 life circuit
Note Proper earthing should be made
50 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 7 ndash WIRING SYSTEM OF THREE PHASE LIGHTING AND POWER CIRCUIT
51 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
52 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify component and the specification
2 Wire component according to the schematic diagram
3 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting bay Board Perforated metal 180 cm x 180 cm 1
2 k Watt hour meter 415V 60A 1
3 MCCB 415V 60A
4 ELCB RCCB In=60A415 Vac I trip=30mA 1
5 5 pin round Socket and
plug
415Vac 32A 4
6 Single pole MCB 6A 1
7 Triple pole MCB 20A 2
8 Triple pole Main switch 60A 1
9 DOL starter 240Vac 2
10 3 phase induction motor 2hp 415 Vac 1
11 1 phase induction motor 1
12 Metal trunking 30 mm x30 mm As required
13 Self tapping Wood screw 4 mm x 20 mm As required
14 DIN rail 25 mm x 1mm
15 GI steel rigid conduit 20mm As required
16 Flexible conduit 20mm As required
17 End box 20 mm 4
18 Flexible wires 05 mm As required
19 Connectors 10 A As required
Procedures
1 Identify each components and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
4 Test the functionality of completed project
1 dead circuit 2 life circuit test
5 Record the current drawn by the load as connected in star and delta
Note Proper earthing should be made
53 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 8 INSPECTION AND TESTING OF ELECTRICAL INSTALLATION
On completion of a wiring installation a number of tests on the installation have to be conducted to
ascertain that the wiring circuits and connected appliances are safe for use Prior to carrying out the
tests an inspection has to be done The results of the inspectionsupervision and test have to be
presented in Form G (as in Appendix IV) and Form H (as in Appendix V)
To have the test certification as in Form H the following tests shall be conducted
i Continuity Test
ii Insulation Resistance Test
iii Polarity Test
iv Earth Electrode Resistance test and
v Residual Current Device Test
1 Continuity Test
There are 3 main types of continuity tests for the final circuits-
i Protection Conductor Continuity Test
ii Final Ring Circuit Conductor Continuity Test
iii Live and Neutral Conductor Continuity Test
a) Protection Conductor Continuity Test
bull To ascertain that all protection conductors are connected in the correct and effective manner
bull Test equipment ndash Multimeter (Ohm range) or Ohm meter
54 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
bull Test Method
1 1048766 Ensure that the main switch RCD and MCB are open circuited (switched off) and all loads
are disconnected
2 1048766 Connected the test leads as in the Figure 81 The meter reading shall be less than 1 Ω
55 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Final Ring Circuit Conductor Continuity Test
bull To ensure that all conductors around the ring circuit have continuity
bull Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
bull Test Method
1 1048766 Disconnect both the supply source live conductors from the MCB the neutral conductor
from the neutral terminals and the earth conductor from the earth terminal in the distribution
fuse box
2 1048766 Connect the test leads as in the Figure 82 (EE)
3 1048766 Repeat the procedure for (L-L) and (N-N)
4 1048766 The meter reading value shall be less than 1 ohm
56 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Live and Neutral Conductor Continuity Test
a To ensure that each conductor in the circuit has continuity
b Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
2 Test Method
1 1048766 Switch off the Main switch RCD and MCB
2 1048766 Disconnect all loads
3 1048766 Switch on all switches in the circuit
4 1048766 Disconnect the fusesfinal circuit breakers and close the circuit
5 1048766 Carry out the test as shown in Figure 83
6 1048766 The meter reading value shall be less than 1Ω
57 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
58 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
CONTINUITY TEST
Insulation Resistance Test
i Ensure that there is no leakage current between phase conductors phase and neutral conductors and
phase conductor and earth
ii Test the strength of the cable insulation
iii Test Equipment ndash Insulation Resistance Tester operating voltage is 250VDC or 500VDC
iv Test Method
1 1048766 Switch off main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
59 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
4 1048766 Carry out test as in the Table below
5 1048766 Meter reading value shall be less than 1 Megaohm
60 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
61 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Insulation resitance test
62 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
INSULATION RESISTANCE TEST BETWEEN CONDUCTORS AND OPPOSITE POLARITY
Polarity Testi Ensure that each fuse or single pole control and protection device is connected only in the phase
conductor
ii Intermediate contact of Edison screw lamp holder is connected to the phase conductor
iii Ensure that phase neutral and earth conductors at socket outlets are connected at the correct
terminals
iv Test Equipment ndash Multimeter (Ohm range) or Ohm meter
v Test Method
1 1048766 Switch off Main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in Figure 85
63 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
5 1048766 Test switches and single phase control devices at the phase conductors
6 1048766 Test socket outlet connection sources
7 1048766 Test Edison screw lamp holder connections
8 1048766 Meter reading value shall be less than 1 Ω
64 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Polarity test
65 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Earth Electrode Resistance Testi To test the earth electrode resistance
ii To ascertain the suitability of the location of the electrode
iii To ensure that the electrode is not buried within the resistance area of another electrode
iv Test equipment ndash Earth Resistance Tester
v Test method -
1 1048766 Terminal rsquoErsquo is connected to the electrode to be tested (green conductor)
2 1048766 Terminal lsquoPrsquo is connected to the potential spike (yellow conductor) at a distance of 10
meters from the earth electrode
3 1048766 Terminal lsquoCrsquo is connected to the current spike (red conductor) at a distance of 20 meters
from the earth electrode
Earth Electrode Resistance Measurement Method (Figure 86)
This test must be repeated at least three times to ensure that the reading is not affected by interacting
earthing regions
i Record the first reading (Z1) Example Z1 = 10 Ω
ii Move the voltage spike to a distance of 6 meters from the original position Record the second
reading (Z2 ) Example Z2 = 10 Ω
iii Move the voltage spike to a distance of 6 meters from the original position Record the third
reading (Z3) Example Z3 = 10 Ω
66 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Residual Current Device Testi Ensure that the residual current device (RCD) trips within the set time on the occurrence of current
leakage to earth
ii Test Equipment ndash RCD Tester RCCB Tester
iii Test Method 1
1 1048766 Use the Trip Test Button
2 1048766 Press the trip button found on the RCD to determine if it trips or otherwise This test would
not be able to determine the sensitivity of the RCD nor the time taken for it to trip
iv Test Method 2
i 1048766 Use a RCD Tester
ii This equipment is equipped with a 13A plug which can be connected to a 13A socket outlet
Select the RCD sensitivity to be the same as the sensitivity of the RCD to be tested to
determine if the RCD can trip The time to trip shall not exceed 40 mS
iii 1048766 Test method ndash
a) Position the selection switch in accordance with the sensitivity of the RCD used
Example 100 mA 01 A
b) Position the operations switch to lsquoNo Triprsquo (frac12 Rated mA = 50) connect the 3 pin plug to
the 13A socket outlet
67 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
c) Switch on the 13A socket outlet ndash ensure that the P-N and P-E lights light up
This shows that the polarity is correct (Note if both the lights as above do not light up the test cannot
be continued)
d) Press the test button ndash the reading shows less than 200 mS and simultaneously the lsquotestrsquo light lights
up and the P-N and P-E lights do not light up At that instant the RCD will not trip
e) Move the selection switch to 180o (+ve wave) ndash repeat steps (d) and (e) Move the operations
switch to lsquoTriprsquo (Rated mA = 100)
g) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200mS
h) Move the selection switch to 0o (-ve wave)
i) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
j) The above test is repeated until a near correct reading is obtained
k) Record the test results
l) Change the operations switch to lsquoFast Triprsquo and press the test button ndash RCD will trip within a
time not exceeding 40 millisecond
m) Repeat a number of times at 0o or 180o
On completion of a wiring installation a number of tests on the installation have to be conducted to
ascertain that the wiring circuits and connected appliances are safe for use Prior to carrying out the
tests an inspection has to be done the following tests shall be conducted
i Continuity Test
ii Insulation Resistance Test
iii Polarity Test
iv Earth Electrode Resistance test and
v Residual Current Device Test
821 Continuity Test
There are 3 main types of continuity tests for the final circuits-
i Protection Conductor Continuity Test
ii Final Ring Circuit Conductor Continuity Test
68 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
iii Live and Neutral Conductor Continuity Test
a) Protection Conductor Continuity Test
bull To ascertain that all protection conductors are connected in the correct and effective manner
bull Test equipment ndash Multimeter (Ohm range) or Ohm meter
bull Test Method
1 1048766 Ensure that the main switch RCD and MCB are open circuited (switched off) and all loads are
disconnected
2 1048766 Connected the test leads as in the Figure 81
3 1048766 The meter reading shall be less than 1 Ω
Final Ring Circuit Conductor Continuity Test
bull To ensure that all conductors around the ring circuit have continuity
bull Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
bull Test Method
1 1048766 Disconnect both the supply source live conductors from the MCB the neutral conductor
from the neutral terminals and the earth conductor from the earth terminal in the distribution
fuse box
2 1048766 Connect the test leads as in the Figure 82 (EE)
3 1048766 Repeat the procedure for (L-L) and (N-N)
4 1048766 The meter reading value shall be less than 1 ohm Figure 82 - Final Ring Circuit Conductor
Continuity Test Ohm Meter
Disconnect both the supply source cables from mcbfuse
Take readings at earth conductors of both sources and note resistance readings
Live and Neutral Conductor Continuity Test
1 To ensure that each conductor in the circuit has continuity
2 Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
3 Test Method
1 1048766 Switch off the Main switch RCD and MCB
2 1048766 Disconnect all loads
3 1048766 Switch on all switches in the circuit
4 1048766 Disconnect the fusesfinal circuit breakers and close the circuit
5 1048766 Carry out the test as shown in Figure 83
6 1048766 The meter reading value shall be less than 1 ohm Figure 83 - Live and Neutral
Conductor Continuity Test Ohm Meter
Insulation Resistance Test
69 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
i Ensure that there is no leakage current between phase conductors phase and neutral conductors and
phase conductor and earth
ii Test the strength of the cable insulation
iii Test Equipment ndash Insulation Resistance Tester Operating voltage is 250VDC or 500VDC
iv Test Method
1 1048766 Switch off main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in the Table below
5 1048766 Meter reading value shall be less than 1 Megaohm
Polarity Test
i Ensure that each fuse or single pole control and protection device is connected only in the phase
conductor
ii Intermediate contact of Edison screw lamp holder is connected to the phase conductor
iii Ensure that phase neutral and earth conductors at socket outlets are connected at the correct
terminals
iv Test Equipment ndash Multimeter (Ohm range) or Ohm meter
v Test Method
1 1048766 Switch off Main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in Figure 85
5 1048766 Test switches and single phase control devices at the phase conductors
6 1048766 Test socket outlet connection sources
7 1048766 Test Edison screw lamp holder connections
8 1048766 Meter reading value shall be less than 1 Ω
Earth Electrode Resistance Test
i To test the earth electrode resistance
70 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
ii To ascertain the suitability of the location of the electrode
iii To ensure that the electrode is not buried within the resistance area of another electrode
iv Test equipment ndash Earth Resistance Tester
v Test method -
1 1048766 Terminal rsquoErsquo is connected to the electrode to be tested (green conductor)
2 1048766 Terminal lsquoPrsquo is connected to the potential spike (yellow conductor) at a distance of 10
meters from the earth electrode
3 1048766 Terminal lsquoCrsquo is connected to the current spike (red conductor) at a distance of 20 meters
from the earth electrode E P C Electrode 10 meter 10 meter
Figure 86 ndash Earth Electrode Resistance Measurement Test Equipment
Earth Electrode Resistance Measurement Method (Figure 86)
This test must be repeated at least three times to ensure that the reading is not affected by interacting
earthing regions
i Record the first reading (Z1) Example Z1 = 10 Ω
ii Move the voltage spike to a distance of 6 meters from the original position Record the second
reading (Z2) Example Z2 = 10 Ω
iii Move the voltage spike to a distance of 6 meters from the original position Record the third
reading (Z3)
Example Z3 = 10 Ω
Residual Current Device Test
71 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
i Ensure that the residual current device (RCD) trips within the set time on the occurrence of current
leakage to earth
ii Test Equipment ndash RCD Tester RCCB Tester
iii Test Method 1
1 1048766 Use the Trip Test Button
2 1048766 Press the trip button found on the RCD to determine if it trips or otherwise This test would
not be able to determine the sensitivity of the RCD nor the time taken for it to trip
iv Test Method 2
1048766 Use a RCD Tester
This equipment is equipped with a 13A plug which can be connected to a 13A socket outlet Select the
RCD sensitivity to be the same as the sensitivity of the RCD to be tested to determine if the RCD can
trip The time to trip shall not exceed 40 mS
1048766 Test method ndash
a) Position the selection switch in accordance with the sensitivity of the RCD used
Example 100 mA 01 A
b) Position the operations switch to lsquoNo Triprsquo (frac12 Rated mA = 50) connect the 3 pin plug to
the 13A socket outlet
c) Switch on the 13A socket outlet ndash ensure that the P-N and P-E lights light up This shows that
the polarity is correct (Note if both the lights as above do not light up the test cannot be
continued)
d) Press the test button ndash the reading shows less than 200 millisecond and simultaneously the
lsquotestrsquo light lights up and the P-N and P-E lights do not light up At that instant the RCD will
not trip
e) Move the selection switch to 180o (+ve wave) ndash repeat steps (d) and (e) = 100)
f) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
g) Move the selection switch to 0o (-ve wave)
h) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
i) The above test is repeated until a near correct reading is obtained
j) Record the test results
k) Change the operations switch to lsquoFast Triprsquo and press the test button ndash RCD will trip within a
time not exceeding 40 mS
l) Repeat a number of times at 0o or 180o
72 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 9 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (DC)
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
73 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Start stop button 240Vac 5A 2
9 Filament lamp (Bulb ) 240Vac 40W 3
10 Overload Relay 415V 20A 3
11 Three phase induction motor 5 hp 3
12 Single phase step down transformer 2500VA 1
13 Single core PVC insulated Cable 1mm 2 As required
14 Single core PVC insulated Cable 25mm 2 As required
15 DIN rail 35 mm As required
16 PVC type Cable tray 50 mm x 50 mm As required
17 Cable ties 4 ldquo As required
18 Flexible wires 05 mm As required
19 PVC Connectors 5 A amp 20 A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the schematic
diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a optional exercise
i Simple DOL starter
ii Forward reverse DOL starter
iii Forward Reverse Dahlander motor
iv Three motors operated in sequence by DOL starter operated by manual push
button or time delay relay
74 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
a One loop per-cycle
b Continuous operation in a loop
c optional circuit design to represent the same task
v Only one out of three motors to be operated at a time (quiz)
4 Test the functionality of completed project
LESSON 10 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (AC)
75 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 1
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Lamp point 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
76 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
11 Overload Relay 415V 20A 3
12 Three phase induction
motor
5 hp 3
13 Single core PVC insulated
Cable
1mm 2 As required
14 Single core PVC insulated
Cable
25mm 2 As required
15 DIN rail 35 mm As required
16 PVC type Cable tray 50 mm x 50 mm As required
17 Cable ties 4 ldquo As required
18 Flexible wires 05 mm As required
19 PVC Connectors 5 A amp 20 A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the
schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram optional exercise
4 Simple DOL starter
5 Forward reverse DOL starter
6 Test the functionality of completed project
77 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 1
78 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
cm
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Indicating light 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
11 Overload Relay 415V 20A 3
12 Three phase induction motor 5 hp 3
13 Single phase step down
transformer
2500VA 1
14 Single core PVC insulated
Cable
1mm 2 As required
15 Single core PVC insulated
Cable
25mm 2 As required
16 DIN rail 35 mm As required
17 PVC type Cable tray 50 mm x 50 mm As required
18 Cable ties 4 ldquo As required
19 Flexible wires 05 mm As required
20 PVC Connectors 5 A amp 20 A 240 V As required
21 Single pole MCB 6A 240 V 1
22 Single pole MCB 2A 240 V 1
23 Triple pole MCB 20A 415 V 1
24 Mounting board 30 cm x 40 cm x 3
cm
1
25 Relay cw 11 pin socket 10 A 240 Vac 2
26 Time delay relay 10 A 240 Vac 3
27 Triple pole Contactor 20A 240Vac 3
28 Batten type Lamp holder 240Vac 10 A 3
29 Start stop button 240Vac 10A 2
30 Indicating light (Bulb ) 240Vac 25W 3
31 Overload Relay 415V 20A 1
32 Three phase dahlander type
induction motor
5 hp 1
33 Single phase step down
transformer
24024Vac
2500VA
1
79 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
34 Single core PVC insulated
Cable
1mm 2 As required
35 Single core PVC insulated
Cable
25mm 2 As required
36 DIN rail 35 mm As required
37 PVC type Cable tray 50 mm x 50 mm As required
38 Cable ties 4 ldquo As required
39 Flexible wires 075 mm As required
40 PVC Connectors 5 A amp 20 A 240 V As required
41 Terminal block 20A 240Vac As required
Procedures
5 Identify each component according to specification and quantity required from the schematic
diagram attached
6 Test the functionality of each component by using multi-meter or power supply whichever
applicable
7 Wire component according to circuit diagram
8 Three motors operated in sequence by DOL starter operated by manual push button or time
delay relay
a One loop per-cycle
b Continuous operation in a loop
c optional circuit design to represent the same task
d Only one out of three motors to be operated at a time (quiz)
9 Test the functionality of completed project
80 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
BASIC DESIGN INDUSTRIAL MOTOR CONTROL (SEQUENCE CONTROL)
THREE PHASE INDUCTION MOTOR OPERATED IN SEQUENCE BY DIRECT ON LINE
STARTER
LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
81 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
82 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Lcd lamp indicator 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
11 Overload Relay 415V 20A 3
12 Three phase induction motor 5 hp 3
13 Single phase step down transformer 2500VA 1
14 Single core PVC insulated Cable 1mm 2 As required
15 Single core PVC insulated Cable 25mm 2 As required
16 DIN rail 35 mm As required
17 PVC type Cable tray 50 mm x 50 mm As required
18 Cable ties 4 ldquo As required
19 Flexible wires 1 mm Oslash As required
20 PVC Terminal block 10A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the schematic
diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a optional exercise
i Forward Reverse dahlander motor
4 Test the functionality of completed project
83 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
THREE PHASE DAHLANDER TYPE INDUCTION MOTOR OPERATED FORWARD AND
REVERSE OPERATION BY DIRECT ON LINE STARTER
84 ndash 99EASYTECH ENTERPRISE
LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
Introduction
If a motors windings are connected in the star configuration any two phases will be in series across
the supply and hence the line current will be smaller(by 577) than if the windings were connected in
the delta arrangement
Hence larger-type motors with heavy starting currents are first connected in star and then when the
starting currents fall in delta This of course means that all six of the ends of the windings must be
brought to terminations outside the casing (Fig 833)
EZTECH
EZTECH ELECTRICAL INSTALLATION GUIDE
The automatic version of this starter incorporates a timing relay which automatically changes the
connections from star to delta Figs 834 and 835 show the wiring and schematic diagrams for a star
delta starter
Objectives
1 Identify component and the specification
2 Design forward reverse star delta starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
2 ndash 99EASYTECH ENTERPRISE
REV -C
LEGENDMCCB Moulded Case Circuit BreakerTOR Thermal Over Load RelayFOW-C Mains Forward ContactorREV-C Mains Reverse ContactorDC Delta ContactorSC Star ContactorS-SW Mains Selector Switch
SC
V2
W2
U2
DC
V1
W1
U1
TOR
TOR
FOW-C
30A MCCB
TOR
MAIN CIRCUIT FORWARD REVERSE STAR DELTA
RYBN S
-SW
3 PHASEINDUCTION MOTOR
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Relay 10 A 240V 3
5 Triple pole Contactor
6 cw NO NC auxiliary contact
240Vac 20 A 4
7 Overload Relay 415 V 1
8 LED indicator 240vac 5 A 4
9 Start stop button 240Vac 5A 2
10 DIN rail 35 mm As required
11 Flexible wires 1 mm As required
12 Single core PVC insulated
wire
25 mm As required
13 Terminal block 20 A As required
14 Squirrel cage motor 5kW 1
15 5 pin plug and socket 415V 20A 1
16 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
3 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
a Manual star delta
b Manual Forward reverse star delta starter
c Automatic star delta starter
d Automatic Forward reverse star delta starter
4 Test the functionality of completed project
4 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
Objectives
1 Identify component and the specification
2 Design auto transformer starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
5 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Autotransformer starter is used to start a 3 phase induction motor that has a rating between 10 to 15 hp
6 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Autotransformer set 10Kw 415 V 50 Hz 1
5 Triple pole Contactor 240Vac 4
6 Batten type Lamp holder 240 Vac 105 A 4
7 Start stop button 240Vac 10A 4
8 Filament lamp (Bulb ) 240Vac 40W 4
9 DIN rail 35 mm As required
10 Flexible wires 1 mm As required
7 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
11 Single core PVC insulated
wire
25 mm As required
12 Terminal block 20 A As required
13 Squirrel cage motor 10kW 1
14 5 pin plug and socket 415V 20A 1
15 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a open transient autotransformer starter
b close transient autotransformer starter
c Forward reverse autotransformer starter
4 Test the functionality of completed project
8 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
Objectives
1 Identify component and the specification
2 Design rotor resistance starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
9 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Rotor Resistor set 10kW 1
5 Triple pole Contactor 240Vac 20A 4
6 Indicating light 240vac 5 A 4
7 Start stop push button 240Vac 5A 4
8 DIN rail 35 mm As required
9 Flexible wires 1 mm 2 As required
10 Single core PVC insulated wire 25 mm 2 As required
11 Terminal block 20 A As required
12 Slip Ring motor 10kW 1
13 5 pin round 3 phase socket 415V 20A 1
14 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
10 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
4 Test the functionality of completed project
a Dead circuit test b Life circuit test
5 Measure starting and running Amps
LESSON 16
TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
An installation in general will suffer damage
Damage usually occurs on the electric motor control as follows
1 Damage to the main circuit
2 Damage to the control circuit
The cause of the damage
i Overcurrent overload short circuit
ii Leakage current to ground
iii Equipment malfunction
iv The main control circuit
a Trip of main circuit protection devices fire
b Defect of motor terminal such as short circuit fire loose
v The control circuit is not functioning -
a contactor relay relay time overload relay does not work damaged burned
b Loose cable connection disconnected
Detecting and Repairing Damage
Examples of damage are as follows
i Motor does not work
ii Motor function and overload relay trips
iii Motor function but only partially functional control circuit
Methods of detecting damage
Among the known methods necessary to detect damage are as follows
1 Turn off the electricity at the main switch (main switch) in order to avoid any danger during the
work carried out to detect damage
2 Check all the protective gear that controls the motor control main circuit
11 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
3 Make sure the damage function control circuit
4 Check the control circuit according to the schematic circuit diagram of the motor control
5 Check the operation of the control circuit
Note
Use wiring that has been installed on the SYSTEM OF MOTOR CONTROL BOARD by Forward
Reverse control circuit for Star Delta to test and look for damage
SELF-ASSESSMENT QUESTIONS
1 (a) Explain what is meant by the term lsquoback emfrsquo in a motor
(b) Outline the basic differences between series shunt and compound wound dc motors
2 (a) With the aid of diagrams explain how the speed of series shunt and compound-wound motors
may be controlled
(b) A 440V dc shunt-wound motor has a field resistance of 200R and an armature resistance of 06 R
When its speed is 20 rev d second the current drawn from the supply is 122A Calculate its back
emf at this speed If the speed were decreased to 19 revssecond the field flux remaining unchanged
calculate the new back emf and the new armature current
3 A load of 64 kW at 240 V is supplied from the terminals of a shunt-wound dc generator The field
resistance is 180 A Calculate the armature current
4 (a) Explain with the aid of a diagram how a rotating magnetic field may be
(b) What is meant by lsquosynchronous speedrsquo
Calculate the synchronous obtained speed of a 12 pole motor if the supply frequency is 50Hz
5 (a) Explain the action of a synchronous motor
(b) What methods are available to start a synchronous motor Explain with diagrams
6 (a) Explain the action of a cage induction motor
(b) What is meant by the term lsquosliprsquo
Calculate the percentage slip of a six pole induction motor running at 162 revssecond from a 50 Hz
supply
7 Describe with sketches three different ways of starting a single-phase induction motor
12 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
8 Explain with the aid of a sketch the action of a three-phase DOL starter
What are dashpots used for How are remote start and stop buttons connected
9 A I0 kW 240V 50Hz single-phase cage rotor induction motor is 85efficient and has a PF of 068
lagging Calculate the motor current and the value of capacitor required to raise the PF to 093
lagging
10 Calculate the torque developed by an 18 kW four-pole induction motor run at 35 slip from a
50Hz supply
APPENDIX 1
13 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 11
14 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 111
Attachment Reference
httpswwwtlc-directcoukBook621htm
httpwwwstgovmyindexphpms
15 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
21 Selection of Control and Protection System for Electrical Wiring
Control and protection of a wiring is a system of separationisolation and switching together with the
protection system which are needed in every domestic wiring installation
22 Isolation and Switching
Examples of isolation and switching are switches power plugs socket outlets and circuit breakers
Their function is to manually connect and break the supply in a particular circuit without interfering
with other circuits
They also aim to prevent the danger of electrical shocks during maintenance testing fault finding and
repair works
23 Protection
This provides protection from dangers caused by electrical currents such as over current earth
leakage current short circuit lightning etc to the wiring system electrical equipment or consumer
The circuit below shows the isolation and protection devices which must be installed in a domestic
electrical wiring system
1 Current Protection
In general protection from the dangers of current can be divided into two aspects namely
i Overcurrent Protection (Over Load or Short Circuit) Properly rated circuit breakers or fuses suitable
for over load or short circuit protection must be used
9 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
The circuit breakers or fuses must be installed on the live conductors only For three phase circuits all
the circuit breakers or fuses must be combined in one set of circuits
Selection of over current devices must be based on the short circuit fault current levels of the circuit
breaker or main switch (kA)
ii Earth Leakage Current Protection
Properly rated Residual Current Devices (RCD) must be used for protection from earth leakage
currents (to prevent electric shocks)
a) Regulation 36(1) of the Electricity Regulations 1994 states that for a place of public entertainment
protection against earth leakage current must be provided by a residual current device of sensitivity
not exceeding 10 mA
b) Regulation 36(2) of the Electricity Regulations 1994 states that for a place where the floor is likely
to be wet or where the wall or enclosure is of low electrical resistance protection against earth leakage
current must be provided by a residual current device of sensitivity not exceeding 10 mA
c) Regulation 36(3) of the Electricity Regulations 1994 states that for an installation where hand-held
equipment apparatus or appliance is likely to be used protection against earth leakage current must be
provided by a residual current device of sensitivity not exceeding 30 mA and
d) Regulation 36(4) of the Electricity Regulations 1994 states that for an installation other than the
installation in (a) (b) and (c) protection against earth leakage current must be provided by a residual
current device of sensitivity not exceeding 100 mA
CABLE SELECTION
31 Selection of Wiring Cable Type
The selection of the cable size has to take into consideration the following-
i All wiring cables must be PVC or PVCPVC insulated with copper conductors Conductors with
cross sectional areas of 16mm2 or less must be of copper Aluminium conductors are not permitted
Refer to Table 4D1A in Appendix II for the current carrying capacities of copper conductor
ii Cables for swimming pools must be water resistant PE (polyethylene) insulated
10 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
iii The selected cable must be capable of delivering the electrical energy efficiently
iv The cable size allows it to carry the current without heating the cable
v The voltage drop must not exceed 4 of the supply voltage Refer to Table 4D1B in Appendix III
vi The cable insulation must be suitable for the surrounding conditions of the installation such as the
ability to withstand the surrounding temperatures and the ability to provide mechanical protection
vii Each conductor in the installation must be protected from overcurrent by means of overcurrent
protection devices needed to prevent damage to the cable insulation
32 Factors Related to Cable Current Carrying CapacityThe following factors in relation to the current carrying capacity of cables must be taken into
consideration-
i Surface wiring using clips ndash group factor
ii Wiring using conduits ndash space factor 40
iii Wiring using ducts ndash space factor 45
iv Concealed wiring ndash group factor and
v Concealed wiring using ducts ndash surrounding temperature factor
Use of Minimum Cross Sectional Area Rating of Wiring ConductorsThe following are the minimum cross sectional areas of conductors based on their applications-
Use of Protection Conductor Minimum Cross Sectional Area Rating
In Comparison with Phase Conductor Cross Sectional Area
The following table shows the protection conductor minimum cross sectional area in comparison
with the phase conductor cross sectional area
Functions and Colour Identification of Non Flexible Cables
The following table shows the functions and colour identification of non flexible cables
11 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
33 Use of Minimum Cross Sectional Area Rating of Wiring Conductors
The following are the minimum cross sectional areas of conductors based on their applications-
34 Use of Protection Conductor Minimum Cross Sectional Area Rating
In Comparison with Phase Conductor Cross Sectional Area
The following table shows the protection conductor minimum cross sectional area in comparison
with the phase conductor cross sectional area
Use of Minimum Cross Sectional Area Rating of Wiring Conductors
The following are the minimum cross sectional areas of conductors based on their applications-
Use of Protection Conductor Minimum Cross Sectional Area Rating
In Comparison with Phase Conductor Cross Sectional Area
The following table shows the protection conductor minimum cross sectional area in comparison
with the phase conductor cross sectional area
Functions and Colour Identification of Non Flexible CablesThe following table shows the functions and colour identification of non flexible cables
12 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Flexible Cables
i Flexible cables of cross sectional area less than 40 mm2 are used in installations for electrical
accessories such as ceiling roses lamp fixtures or attachments socket plugs for mobile
appliances etc
ii Flexible cables shall not be used for permanent wiring
iii Flexible cables for the permanent use of electrical appliances should not exceed 3 meters in
length
37 Functions and Colour Identification of Flexible Cables
Conductor Insulation and Types of WiringVarious material and insulation layers are used for conductor protection Cable selection in
accordance to insulation layers must be done correctly for the type of the wiring installation as
shown in the table below
Functions and Colour Identification of Non Flexible CablesThe following table shows the functions and colour identification of non flexible cables
3 SELECTION OF WIRING ACCESSORIES
i All wiring accessories to be used have to be of those approved by the Energy Commission and
labeled with labels issued by SIRIM For all wiring using UPVC conduits -
13 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
a) Switches socket outlets 3 pin plugs ceiling roses connectors sockets ndash construction material shall
be of polycarbonate type
iii For all wiring using metal conduits - Switches socket outlets and connectors ndash construction
material shall be of metal clad type and All accessories shall be effectively earthed
iv Switch fuse used in single phase installations shall have the fuse permanently connected and not
move with the fuse
v Fuse switch used in 3 phase domestic installations also has fuse and switch The fuse connector is
installed together to allow the fuse to move simultaneously with the switch
vi Lamp
a) Fluorescent lamps using magnetic ballasts (watt loss not exceeding 6 watts) shall be
equipped with dry paper type capacitor
b) Fluorescent lamps using electronic ballasts or high frequency electronic ballasts do not
need capacitors
c) Outdoor domestic lamp installations shall use weather proof and water proof lamps
d) Submerged light installations (example in swimming pools fountains etc) shall have water
proof lamps with a voltage not exceeding 12 Volt AC
vii Electric water heaters is divided into 2 types namely
1 instantaneous water heaters and
2 stored water heaters (storage tank type)
a) Instantaneous water heaters shall be equipped with a 2 pole control switch and its own
residual current device
b) Storage water heaters (storage tank type) shall be installed with an
Water heaters exceeding 3kW shall be permanently connected to a 20A30A rated circuit
breakerfuse with an isolator switch and residual current device
viii Electric cookers exceeding 3kW shall have its own circuit connected permanently to a 30A rated
circuit breaker or fuse with an isolator switch and cooker control unit incorporated with a 13A socket
outlet Two or more cooker appliances may be installed in the same room within a distance of 2
meters
ix Electric motors (fence gate air conditioners fountains swimming pools fish ponds water
pumps) exceeding 373W but not exceeding 2238W shall be connected permanently to a 20A30A
rated circuit breakerfuse together with an isolator motor starter and 15A socket outlet
14 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
The motor starter shall be of Direct-On-Line type with the appliance together with the contactor
overload relay and on-off control The circuit breakerfuse which controls the motor circuit shall be
capable of withstanding the starting current of the motor
x Electric bells ndash the circuit shall have a push button switch and a ACDC transformer
xi Ceiling fans shall conform to clause 21101 of the MS 12192002 standard with regards to test on
the suspension system of ceiling fans
EARTHING OF ELECTRICAL INSTALLATIONS51 Earthing
Earthing is a connection system between the metallic parts of an electrical wiring system and the
general mass of the earth This will provide an easy path with a low impedence or resistance to earth to
enable the protection system to operate effectively It will thus ensure safety to human
beingsconsumers from the dangers of electric shocks if earth leakage currents are present In general
an electrical installation is earthed because of -
i Safety reasons
ii Protection system requirements
iii Need to limit over voltages
iv Need to provide a path for electrical discharge
v Legal requirements
52 Classification of Earthing
Generally earthing can be divided into 2 parts namely -
i System Earthing
a To isolate the system under fault conditions
b To limit the potential difference between conductors which are not insulated in an area
c To limit the occurrence of over voltages under various conditions
ii Equipment Earthing
Equipment earthing is undertaken to protect human beingsconsumers If a live source comes into
contact with the equipment body electrical energy will flow to the earth without flowing through the
human being consumerrsquos body This is because of the fact that the human body has a greater
resistance compared with the resistance to earth
53 Types and Functions of Earthing Accessories
Earthing accessories are as follows -
i Earthing Electrode
Copper jacketed steel core rods are used as electrodes for domestic wiring
ii Equipotential Bonding
15 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
This is the conductor which is connected between the consumer earthing point and the exposed
metallic part The minimum cable size for this purpose is 10 mm2
iii Protection Conductor
This is the conductor which connects the consumer earthing point with other parts of the installation
which needs earthing Its size is as follows-
a) Same size as the phase cable up to a size of 16mm2
b) 16 mm2 if the phase cable size is between 16 mm2 and 35 mm2
c) Half the size of the phase cable if the size of the phase cable exceeds 35 mm2
54 Earthing Arrangements Using a TT System
i The first alphabet indicates the earthing arrangements from the supply side
ii The second alphabet indicates the earthing arrangement in the consumerrsquos installation
T ndash first Indicates that the supply system has its own earthing arrangements
T ndash second Indicates that all metallic frames of the electrical appliances etc are connected directly to
earth
Parts that are Required to be Earthed
i All metallic structures in the wiring system (non current carrying) such as metallic covers conduits
ducts the armour of catenary wires etc
ii A secondary winding point in a transformer and
iii Frame of metal roof truss
56 Parts that are not Required to be Earthed
i Short isolated metallic parts for mechanical protection of cables which have non metallic sheaths
other than conduits which are connected at entry points between the building and conduits which
protect discharge lamp cables
ii Cable clips for installing cables
iii Metallic covers for lamps
16 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
iv Small metallic parts such as screws and name plates which are isolated by means of insulation
v Metallic lamp parts for filament lamps in water proof floors
57 Termination to Earth
The termination to earth is done as shown in Figure 72
Earth Electrode Resistance
The maximum permitted earth electrode resistance for different types of installations is as shown in
the Table below
Earth electrode for installations protected by RCDs of sensitivity 100mA 10 Ω
Lightning arrestor earth electrode 10 Ω
Legal Requirements
i Sub regulation 12(1) and 12(2) of the Electricity Regulations 1994 state that any electrical wiring in
an installation shall be under the immediate supervision of a Wireman with Single Phase Restriction or
Three Phase Restriction Upon completion the Wireman shall certify a Supervision and Completion
Certificate
ii Sub regulation 13(1) and 13 (2) of the Electricity Regulations 1994 state that the installation shall
be tested by a Wireman with Single Phase Restriction or a Wireman with Three Phase Restriction
authorized to test any installation and who shall certify a Test Certificate for the installation
iii Sub regulation 14(1) of the Electricity Regulations 1994 states that the Supervision and
Completion Certificate and the Test Certificate as in regulations 12 and 13 shall be in Forms G and H
respectively as prescribed in the First Schedule
17 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
4 SAFETY REQUIREMENTS FOR ELECTRICAL WIRING WORKS IN RESIDENTIAL BUILDINGS
61 Safety Requirements
Safety requirements for electrical wiring works have to be followed to eliminate any accidents which
can result in physical damage or loss of life or property Failure to meet the safety regulations may
result in workers consumers or the public being inflicted with electrical shocks
In addition to this safety steps will also encourage workers or electricity consumers who are
disciplined and who always give importance to safety
62 Safety Steps
Safety requirements have to be followed whenever electrical works are undertaken in a residential
building
i Personal Safety
a Use suitable personal protection equipment as needed such as safety shoes gloves safety helmet
etc when at the work place
b Use safety clothing suitable for the work to be undertaken
c Do not wear jewellery or decorative items such as rings watches chains etc while carrying out
electrical works
ii Safety at the Work Place
a Acquire knowledge about the dangers of electrical works that is to be undertaken and how to deal
with those dangers
b Always adhere to the safety regulations which have been set for the work place
c Ensure that the electricity supply is switched off before carrying out the works
d Acquire the needed knowledge and practice a cautious and calm attitude while working ensure
cleanliness in and around fellow workers
e While working at elevated places the worker should always use suitable equipment such as wooden
or aluminium ladders iron scaffoldings or platforms safety belts or other equipment needed to ensure
that the work can be undertaken safely
f Use electrical equipment which is operational and safe to be used and ensure that the supply for it is
being supplied through a residual current device (RCD) with a sensitivity of 30 mA
g Ensure that exposed temporary supply electrical cables have mechanical protection
h If inflammable or corrosive material is present necessary safety steps have to be undertaken as
required by the relevant safety regulations
63 Dangers of Electrical Shocks
i Electrical Shock
Electrical shocks can occur due to direct or indirect contact
a Direct Contact
18 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Direct contact occurs when the worker or consumer receives an electrical shock on touching directly a
live conductor or cable
b Indirect Contact
Here the electric shock occurs due to contact with a part which is connected to the electrical
installation and not to a direct contact with a live cable or conductor possibly due to damages in the
appliance or insulation resulting in leakages of current
Why Electric Shocks Occura Unsafe Work Method or Action Undertaking Electrical Work Without Disconnecting the
Supply
Maintenance or circuit testing work done without disconnecting the supply will have a high possibility
of electrical shocks occurring
bull Not Following Safe Work Procedures
To eliminate the occurrence of electrical shocks each worker has to always follow safe work
procedures which are set by regulations and standards
b Defects in the Electrical System
i Leakage Current
Leakage currents or earth leakage currents can result in the metallic frames becoming live and
energised This can give rise to the danger of electrical shock to the worker consumer or the public if
they hold or come into contact with the metallic frame
ii Exposed Conductor or Disconnected Cable
Exposed conductors or cables which are broken and are alive (energised) can result in electrical shock
when touched The supply source must be immediately isolated or switched off and a report must be
made to the responsible entity
64 First Aid and Basic Pulmonary Resuscitation
i First Aid
First aid is the initial assistance given to a person who has met with an accident is sick or is injured to
prevent the condition of the victim from becoming more serious while awaiting the arrival of the
paramedics (ambulance) or before being brought to the hospital
i Pulmonary Resuscitation
Pulmonary resuscitation has to be undertaken to assist the victim who has breathing difficulties as a
result of being drowned receiving an electrical shock etc Pulmonary resuscitation has to be carried
out in accordance to the correct method as stated in the first aid manuals issued by accredited first aid
bodies
ii First Aid Box
19 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
A first aid box has to be provided by the building owner construction site supervisor or brought
personally by the worker under the supervision of the responsible person
65 Training Programme
The management shall conduct periodic training programmes for the workers with regards to work
safety on aspects including the following -
i Dangers of electrical work being undertaken and how to control those dangers
ii The safety regulations set for the work place and
iii First aid procedures
66 Fire Prevention
Fire Extinguisher A suitable functioning fire extinguisher to control fires has to be made available at
the work place at all times
67 Competent Person
The Electricity Regulations 1994 require that all electrical work has to be undertaken by or under the
direct supervision of a competent person registered with the Energy Commission Besides that the
electrical contractor undertaking the electrical work has also to be registered with the Energy
Commission The installation owner thus has to ensure that the appointed electrical contractor is
registered with the Energy Commission and that the registration is still valid
INSTALLATION CIRCUITS AND SYSTEMS1 Block diagrams
These show using squares rectangles etc the sequence of a system without too much technical detail
eg Figures 1517 and 1526
2 Layout diagrams
These are very similar to block diagrams but they indicate more technical detail and tend to show
items in their correct geographical location (eg Figures 1518 and 1519)
3 Circuitschematic
These show how a circuit functions and takes no account of exact locations of terminals or equipment
(eg Figures 1528 1529 1532 1534 etc)
4 Wiring diagram
These indicate how a circuit or system is physically wired (eg Figures 152 154 156 etc)
Most induction motors are started directly on line but when very large motors are started that way
they cause a disturbance of voltage on the supply lines due to large starting current surges To limit the
starting current surge large induction motors are started at reduced voltage and then have full supply
voltage reconnected when they run up to near rotated speed Two methods are used for reduction of
starting voltage are star delta starting and auto transformer stating
20 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Working Principal of Star-Delta Starter
This is the reduced voltage starting method Voltage reduction during star-delta starting is achieved by
physically reconfiguring the motor windings as illustrated in the figure below During starting the
motor windings are connected in star configuration and this reduces the voltage across each winding 3
This also reduces the torque by a factor of three After a period of time the winding are reconfigured as
delta and the motor runs normally
StarDelta starters are probably the most common reduced voltage starters They are used in
an attempt to reduce the start current applied to the motor during start as a means of reducing the
disturbances and interference on the electrical supply
Traditionally in many supply regions there has been a requirement to fit a reduced voltage
starter on all motors greater than 5HP (4KW) The StarDelta (or WyeDelta) starter is one of the
lowest cost electromechanical reduced voltage starters that can be applied
The StarDelta starter is manufactured from three contactors a timer and a thermal overload
The contactors are smaller than the single contactor used in a Direct on Line starter as they are
controlling winding currents only The currents through the winding are 1root 3 (58) of the
current in the line
There are two contactors that are close during run often referred to as the main contractor and
the delta contactor These are AC3 rated at 58 of the current rating of the motor The third
contactor is the star contactor and that only carries star current while the motor is connected in star
The current in star is one third of the current in delta so this contactor can be AC3 rated at one
third (33) of the motor rating
Star-delta Starter Consists following units
1) Contactors (Main star and delta contactors) 3 Norsquos (For Open State Starter) or 4 Norsquos (Close
Transient Starter)
2) Time relay (pull-in delayed) 1 No
3) Three-pole thermal over current release 1No
4) Fuse elements or automatic cut-outs for the main circuit 3 Nos
5) Fuse element or automatic cut-out for the control circuit 1No
Power Circuit of Star Delta Starter
1 The main circuit breaker serves as the main power supply switch that supplies electricity to the
power circuit
2 The main contactor connects the reference source voltage R Y B to the primary terminal of the
motor U1 V1 W1
21 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
3 In operation the Main Contactor (KM3) and the Star Contactor (KM1) are closed initially and
then after a period of time the star contactor is opened and then the delta contactor (KM2) is
closed The control of the contactors is by the timer (K1T) built into the starter The Star and Delta
are electrically interlocked and preferably mechanically interlocked as well In effect there are
four states
4 The star contactor serves to initially short the secondary terminal of the motor U2 V2 W2 for the
start sequence during the initial run of the motor from standstill This provides one third of DOL
current to the motor thus reducing the high inrush current inherent with large capacity motors at
startup
5 Controlling the interchanging star connection and delta connection of an AC induction motor is
achieved by means of a star delta or wye delta control circuit The control circuit consists of push
button switches auxiliary contacts and a timer
Control Circuit of Star-Delta Starter (Open Transition)
1 The ON push button starts the circuit by initially energizing Star Contactor Coil (KM1) of star
circuit and Timer Coil (KT) circuit
2 When Star Contactor Coil (KM1) energized Star Main and Auxiliary contactor change its
position from NO to NC
3 When Star Auxiliary Contactor (1)( which is placed on Main Contactor coil circuit )became
NO to NC itrsquos complete The Circuit of Main contactor Coil (KM3) so Main Contactor Coil
energized and Main Contactorrsquos Main and Auxiliary Contactor Change its Position from NO
To NC This sequence happens in a friction of time
4 After pushing the ON push button switch the auxiliary contact of the main contactor coil (2)
which is connected in parallel across the ON push button will become NO to NC thereby
providing a latch to hold the main contactor coil activated which eventually maintains the
control circuit active even after releasing the ON push button switch
5 When Star Main Contactor (KM1) close its connect Motor connects on STAR and itrsquos
connected in STAR until Time Delay Auxiliary contact KT (3) become NC to NO
6 Once the time delay is reached its specified Time the timerrsquos auxiliary contacts (KT)(3) in
Star Coil circuit will change its position from NC to NO and at the Same Time Auxiliary
contactor (KT) in Delta Coil Circuit(4) change its Position from NO To NC so Delta coil
energized and Delta Main Contactor becomes NO To NC Now Motor terminal connection
change from star to delta connection
7 A normally close auxiliary contact from both star and delta contactors (5amp6)are also placed
opposite of both star and delta contactor coils these interlock contacts serves as safety
switches to prevent simultaneous activation of both star and delta contactor coils so that one
22 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
cannot be activated without the other deactivated first Thus the delta contactor coil cannot be
active when the star contactor coil is active and similarly the star contactor coil cannot also
be active while the delta contactor coil is active
8 The control circuit above also provides two interrupting contacts to shutdown the motor
The OFF push button switch break the control circuit and the motor when necessary The
thermal overload contact is a protective device which automatically opens the STOP Control
circuit in case when motor overload current is detected by the thermal overload relay this is to
prevent burning of the motor in case of excessive load beyond the rated capacity of the motor
is detected by the thermal overload relay
9 At some point during starting it is necessary to change from a star connected winding to a
delta connected winding Power and control circuits can be arranged to this in one of two
ways ndash open transition or closed transition
What is Open or Closed Transition Starting
(1) Open Transition Starters
Discuss mention above is called open transition switching because there is an open state between
the star state and the delta state
In open transition the power is disconnected from the motor while the winding are reconfigured via
external switching
When a motor is driven by the supply either at full speed or at part speed there is a rotating
magnetic field in the stator This field is rotating at line frequency The flux from the stator field
induces a current in the rotor and this in turn results in a rotor magnetic field
When the motor is disconnected from the supply (open transition) there is a spinning rotor within
the stator and the rotor has a magnetic field Due to the low impedance of the rotor circuit the time
constant is quite long and the action of the spinning rotor field within the stator is that of a
generator which generates voltage at a frequency determined by the speed of the rotor When the
motor is reconnected to the supply it is reclosing onto an unsynchronized generator and this result
in a very high current and torque transient The magnitude of the transient is dependent on the
phase relationship between the generated voltage and the line voltage at the point of closure can
be much higher than DOL current and torque and can result in electrical and mechanical damage
Open transition starting is the easiest to implement in terms or cost and circuitry and if the timing
of the changeover is good this method can work well In practice though it is difficult to set the
necessary timing to operate correctly and disconnectionreconnection of the supply can cause
significant voltagecurrent transients
In Open transition there are Four states
23 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 OFF State All Contactors are open
2 Star State The Main [KM3] and the Star [KM1] contactors are closed and the delta [KM2]
contactor is open The motor is connected in star and will produce one third of DOL torque at one
third of DOL current
3 Open State This type of operation is called open transition switching because there is an
open state between the star state and the delta state The Main contractor is closed and the Delta
and Star contactors are open There is voltage on one end of the motor windings but the other end
is open so no current can flow The motor has a spinning rotor and behaves like a generator
4 Delta State The Main and the Delta contactors are closed The Star contactor is open The
motor is connected to full line voltage and full power and torque are available
(2) Closed Transition StarDelta Starter
There is a technique to reduce the magnitude of the switching transients This requires the use of a
fourth contactor and a set of three resistors The resistors must be sized such that considerable
current is able to flow in the motor windings while they are in circuit
The auxiliary contactor and resistors are connected across the delta contactor In operation just
before the star contactor opens the auxiliary contactor closes resulting in current flow via the
resistors into the star connection Once the star contactor opens current is able to flow round
through the motor windings to the supply via the resistors These resistors are then shorted by the
delta contactor If the resistance of the resistors is too high they will not swamp the voltage
generated by the motor and will serve no purpose
In closed transition the power is maintained to the motor at all time This is achieved by
introducing resistors to take up the current flow during the winding changeover A fourth
contractor is required to place the resistor in circuit before opening the star contactor and then
removing the resistors once the delta contactor is closed These resistors need to be sized to carry
the motor current In addition to requiring more switching devices the control circuit is more
complicated due to the need to carry out resistor switching
In Close transition there are Four states
1 OFF State All Contactors are open
2 Star State The Main [KM3] and the Star [KM1] contactors are closed and the delta [KM2]
contactor is open The motor is connected in star and will produce one third of DOL torque at one
third of DOL current
Star Transition State The motor is connected in star and the resistors are connected across the
delta contactor via the aux [KM4] contactor
24 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Closed Transition State The Main [KM3] contactor is closed and the Delta [KM2] and Star
[KM1] contactors are open Current flows through the motor windings and the transition resistors
via KM4
Delta State The Main and the Delta contactors are closed The transition resistors are shorted out
The Star contactor is open The motor is connected to full line voltage and full power and torque
are available
Effect of Transient in Starter (Open Transient starter)
It is Important the pause between star contactor switch off and Delta contactor switch is on correct
This is because Star contactor must be reliably disconnected before Delta contactor is activated It
is also important that the switch over pause is not too long
For 415v Star Connection voltage is effectively reduced to 58 or 240v The equivalent of 33
that is obtained with Direct Online (DOL) starting
If Star connection has sufficient torque to run up to 75 or 80 of full load speed then the motor
can be connected in Delta mode
When connected to Delta configuration the phase voltage increases by a ratio of V3 or 173 The
phase currents increase by the same ratio The line current increases three times its value in star
connection
During transition period of switchover the motor must be free running with little deceleration
While this is happening ldquoCoastingrdquo it may generate a voltage of its own and on connection to the
supply this voltage can randomly add to or subtract from the applied line voltage This is known as
transient current Only lasting a few milliseconds it causes voltage surges and spikes Known as
a changeover transient
Size of each part of Star-Delta starter
(1) Size of Over Load Relay
For a star-delta starter there is a possibility to place the overload protection in two positions in the
line or in the windings
Overload Relay in Line
In the line is the same as just putting the overload before the motor as with a DOL starter
The rating of Overload (In Line) = FLC of Motor
Disadvantage If the overload is set to FLC then it is not protecting the motor while it is in delta
(setting is x1732 too high)
Overload Relay in Winding
25 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
In the windings means that the overload is placed after the point where the wiring to the contactors
are split into main and delta The overload then always measures the current inside the windings
The setting of Overload Relay (In Winding) =058 X FLC (line current)
Disadvantage We must use separate short circuit and overload protections
(2) Size of Main and Delta Contractor
1 There are two contactors that are close during run often referred to as the main contractor and
the delta contactor These are AC3 rated at 58 of the current rating of the motor
Size of Main Contactor= IFL x 058
(3) Size of Star Contractor
The third contactor is the star contactor and that only carries star current while the motor is
connected in star The current in star is 1 radic3= (58) of the current in delta so this contactor can
be AC3 rated at one third (33) of the motor rating
Size of Star Contactor= IFL x 033
Motor Starting Characteristics of Star-Delta Starter
Available starting current 33 Full Load Current
Peak starting current 13 to 26 Full Load Current
Peak starting torque 33 Full Load Torque
Advantages of Star-Delta starter
The operation of the star-delta method is simple and rugged
It is relatively cheap compared to other reduced voltage methods
Good TorqueCurrent Performance
It draws 2 times starting current of the full load ampere of the motor connected
Disadvantages of Star-Delta starter
Low Starting Torque (Torque = (Square of Voltage) is also reduce)
Break In Supply ndash Possible Transients
Six Terminal Motor Required (Delta Connected)
It requires 2 set of cables from starter to motor
It provides only 33 starting torque and if the load connected to the subject motor requires higher
starting torque at the time of starting than very heavy transients and stresses are produced while
changing from star to delta connections and because of these transients and stresses many
electrical and mechanical break-down occurs
26 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
In this method of starting initially motor is connected in star and then after change over the motor
is connected in delta The delta of motor is formed in starter and not on motor terminals
High transmission and current peaks When starting up pumps and fans for example the load
torque is low at the beginning of the start and increases with the square of the speed When
reaching approx 80-85 of the motor rated speed the load torque is equal to the motor torque and
the acceleration ceases To reach the rated speed a switch over to delta position is necessary and
this will very often result in high transmission and current peaks In some cases the current peak
can reach a value that is even bigger than for a DOL start
Applications with a load torque higher than 50 of the motor rated torque will not be able to start
using the start-delta starter
Low Starting Torque The star-delta (wye-delta) starting method controls whether the lead
connections from the motor are configured in a star or delta electrical connection The initial
connection should be in the star pattern that results in a reduction of the line voltage by a factor of
1radic3 (577) to the motor and the current is reduced to 13 of the current at full voltage but the
starting torque is also reduced 13 to 15 of the DOL starting torque
The transition from star to delta transition usually occurs once nominal speed is reached but is
sometimes performed as low as 50 of nominal speed which make transient Sparks
Features of star-delta starting
1 For low- to high-power three-phase motors
2 Reduced starting current
3 Six connection cables
4 Reduced starting torque
5 Current peak on changeover from star to delta
6 Mechanical load on changeover from star to delta
Application of Star-Delta Starter
The star-delta method is usually only applied to low to medium voltage and light starting
Torque motors
The received starting current is about 30 of the starting current during direct on line start and the
starting torque is reduced to about 25 of the torque available at a DOL start This starting
method only works when the application is light loaded during the start If the motor is too heavily
27 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
loaded there will not be enough torque to accelerate the motor up to speed before switching over
to the delta position
LESSON 1 WIRING SYSTEM OF SINGLE PHASE DISTRIBUTION BOARD
Introduction
28 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
29 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
30 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
31 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 2 WIRING SYSTEM OF SINGLE PHASE LIGHTING CIRCUIT Introduction
Objectives
1 Identify component and the specification
2 Wire component according to the schematic diagram
3 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Wiring bay Perforated metal 180 cm x 180 cm 1
2 Cut out fuse 63 A 240 V 1
3 Neutral link 1
4 Single pole one way switch cw
switch box
5A 240Vac 4
5 single pole two way switch cw
switch box
5A 240Vac 2
6 RCCB In = 40 A Tripping current
100mA240 Vac 50 Hz
1
7 Main switch 32 A 240V 1
8 kWatthour meter 40 A 240 Vac 1
9 Single pole MCB 6A 240 Vac 1
10 Self tapping Wood screw As required
11 DIN rail 35 mm width As required
32 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
12 PVC trunking 50 mm x 50 mm As required
13 Terminal blocks 5 A As required
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
1 One way switch to control one lamp
2 One way switch to control two lamps
3 Two of two way switch to control one lamp
4 Two of single pole two way switch and one of an intermediate switch to control one
lamp
5 One unit of ceiling fan and fan regulator to be controlled by one way switch
4 Test the functionality of completed project
LESSON 3ndash WIRING SYSTEM OF SINGLE PHASE POWER CIRCUIT Introduction
33 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
34 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify types of component and its specification
2 Wire component according to the schematic diagram given
3 Test the functionality of the circuit dead circuit test life circuit test
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board Perforated Metal 1
2 kWh meter 240 V 40 A 1
3 Socket outlet 13A 240Vac 4
4 RCCB 40A Trip Amps
30mA240 Vac
1
5 3 pin socket 240Vac 13A 4
6 Single pole MCB 20A 240 V 2
7 DOL starter 1 kW 240Vac 2
8 1 phase induction motor 2Hp 240 Vac 1
9 Cooker control unit 4kW 240Vac 1
10 Water heater point 4kW 240 Vac 1
11 DIN rail 35 mm As required
12 PVC casing 20mm As required
13 Flexible wires 05 mm As required
14 Terminal block 10 A As required
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Wire two unit of 13 A socket outlet in radial circuit
3 Wire four units of 13 A socket outlet in ring circuit
4 Wire one unit DOL starter for air-conditioner point
5 Wire one unit of cooker control unit point
6 Wire one unit of water heater point
7 Test the functionality of each component by using mmeter or power supply whichever
applicable
8 Wire component according to circuit diagram
9 Test the functionality of completed project dead circuit test life circuit test
Note
35 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Ensure that the correct rating of protection device and size of wire used
LESSON 4ndash CONDUIT BENDING AND TRUNKING FABRICATION TECHNIQUE
Common fitting used in an industrial wiring
Cutting and threading the condute
36 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
37 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
38 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify conduit fitting and the specification
2 Measure and Cut steel conduit according to specified dimension
3 Bend and fabricate conduit at 45 90 according to layout diagram
4 Wire component according to the schematic diagram
5 Test the functionality of the circuit
39 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Conduit Bender Oslash 19 mm ( frac34 ldquo) 1
2 Measuring Tape 3 metre 1
3 Hacksaw frame and blade 30cm 1
4 Conduit cutter 1
5 Pipe Vise 1
6 Pipe Wrench 1
7 Ratchet Dies 20 mm 1
8 Metal trunking 50 mm x 50 mm 1
9 GI conduit 20mm 1
10 End box 20 mm 1
11 Flexible wires 05 mm As required
12 Connectors 5 A As required
13 Single core PVC ins Cable 25 mm 2 As required
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Wire two unit of 13 A socket outlet in radial circuit
3 Wire four unit of 13 A socket outlet in ring circuit
4 Wire one unit DOL starter for air-conditioner point
5 Wire one unit of cooker control unit point
6 Wire one unit of water heater point
7 Test the functionality of each component by using multimeter or power supply whichever
applicable
8 Wire component according to circuit diagram
9 Test the functionality of completed project
Note
Ensure that the rating of protection device and size of wire
K prior to 31 March
2004 (BS 7671)
(formerly)
bare conductor
sleeved at terminations (formerly)
40 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 5 ndashWIRING SYSTEM OF 1 Oslash LIGHTING AND POWER CIRCUIT
POWER CIRCUITSa Radial circuits
Radial circuits are arranged in the same way as item 1 above in lighting layouts in that each socket
outlet is supplied via the previous one
Points to note
1 The number of socket outlets complying with BS 1363 is unlimited for a floor area of up to 50m 2 if
the circuit protection is a 30 A or 32 A cartridge fuse or circuit breaker the cable being 4 mm PVC
copper or 25 mm2 mineral insulated (mi)
2 The number of socket outlets is unlimited for a floor area up to 20 m 2 with any type of circuit
protection of 20 A using 25 mm2 PVC copper cable or 15 mm2 mi
3 The total number of fused spurs is unlimited
b ring final circuits
These circuits are the same as radial circuits except that the final socket outlet is wired back to the
supply position In effect any outlet is supplied from two directions (Fig 152)
Points to note
1 Every twin-socket outlet counts as two single-socket outlets
2 The number of non-fused spurs must not exceed the total number of points on the ring Fig 158
shows seven points on the ring and five spurs
3 The fuse rating of a fused spur box must not exceed 13 A and the current rating of all points supplied
by the fused spur must not exceed 13 A
4 Non-fused spurs must supply no more than one single or one double socket on the ring Fig 158
shows seven points on the ring and five spurs rating of all points supplied by the fused spur must not
exceed 13 A or one stationary appliance
CapacityMain conductor size
copper (mm2)
Earth conductor
size (mm2)
Circuit breaker
capacity (A)
Up to 600 W 15 15 6
600ndash1200 W 1525 15 10
1200ndash1800 W 254 25 16
41 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Ring circuit
(floor area 100 m2)25 15 3032
A2 radial circuit
(floor area 75 m2)40 25 3032
A3 radial circuit
(floor area 50 m2)25 15 20
Air conditioner (15 tonne) 60 60 3032
Cooker 60 60 3032
Water heater 40 40 20
Objectives
1 Identify component and the specification
2 Wire component according to the schematic diagram
3 Test the functionality of the circuit
42 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board Perforated 1
2 Cut out fuse and neutral link 60A 240V 1each
3 kWh meter 240V 40A 1
4 Switched Socket outlet 13A 240Vac 4
5 Single pole two way switch cw switch
box
5A 240Vac 2
6 RCCB ELCB 63 A Tripping current 100mA
415 Vac
1
7 3 pin plug 240Vac 13A 4
8 Single pole MCB 20 A 2
9 Single pole MCB 6A 1
10 Single pole MCB 20A 2
11 DOL starter 240Vac 2
12 1 phase induction motor 2hp 240 Vac 1
13 Self tapping Wood screw As required
14 DIN rail Stainless steel allum35 mm As required
15 PVC pipe 20mm dia As required
16 End box 20 mm dia 4
17 Flexible wires 05 mm 2 As required
18 Connectors 5 A As required
Procedures
43 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
4 Test the functionality of completed project
LESSON 6 ndash WIRING SYSTEM OF 3 Oslash DISTRIBUTION BOARD
Introduction
44 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
45 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
46 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
47 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
48 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify each component and the specification
2 Wire component according to the schematic diagram given
3 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting Board 450 x 600 mm Perforated metal 1
2 5 pin round socket and plug 415V ac 32A 1
3 Cut out fuse 60 A 3
4 Neutral link 1
5 kWatt hour meter 415V 60A 1
6 ELCB RCCB 3P+N In=63A415 Vac I trip= 300mA 1
7 ELCB RCCB 3P+N In=63A415 Vac I trip= 30mA 1
8 Single pole MCB 6A 240 V 3
9 Single pole MCB 20A 240 V 3
10 DOL starter 20 A 240Vac 2
11 Socket outlet 15 A 240 Vac 1
12 Switched Socket outlet 13 A 240 Vac 3
13 Led indicating light 5A 240 Vac 3
14 Single pole 4 gang 1 way switch 5A 240 Vac 2
15 Single pole 2 way switch 5A 240 Vac 2
16 1 phase induction motor 1 kW 240Vac 1
17 Metal trunking 30 mm x30 mm As required
18 Self tapping Wood screw 4 mm x 20 mm As required
19 DIN rail 25 mm x 1mm
20 GI steel rigid conduit 20mm As required
21 Flexible conduit 20mm As required
22 End box 20 mm 4
23 Flexible wires 05 mm 2 As required
24 Single core PVC insulated wire 15 mm 2 As required
25 Single core PVC insulated wires 25 mm 2 As required
26 Terminal block 10 A As required
Procedures
49 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify each components and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
4 Test the functionality of completed project
1 dead circuit test
2 life circuit
Note Proper earthing should be made
50 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 7 ndash WIRING SYSTEM OF THREE PHASE LIGHTING AND POWER CIRCUIT
51 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
52 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify component and the specification
2 Wire component according to the schematic diagram
3 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting bay Board Perforated metal 180 cm x 180 cm 1
2 k Watt hour meter 415V 60A 1
3 MCCB 415V 60A
4 ELCB RCCB In=60A415 Vac I trip=30mA 1
5 5 pin round Socket and
plug
415Vac 32A 4
6 Single pole MCB 6A 1
7 Triple pole MCB 20A 2
8 Triple pole Main switch 60A 1
9 DOL starter 240Vac 2
10 3 phase induction motor 2hp 415 Vac 1
11 1 phase induction motor 1
12 Metal trunking 30 mm x30 mm As required
13 Self tapping Wood screw 4 mm x 20 mm As required
14 DIN rail 25 mm x 1mm
15 GI steel rigid conduit 20mm As required
16 Flexible conduit 20mm As required
17 End box 20 mm 4
18 Flexible wires 05 mm As required
19 Connectors 10 A As required
Procedures
1 Identify each components and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
4 Test the functionality of completed project
1 dead circuit 2 life circuit test
5 Record the current drawn by the load as connected in star and delta
Note Proper earthing should be made
53 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 8 INSPECTION AND TESTING OF ELECTRICAL INSTALLATION
On completion of a wiring installation a number of tests on the installation have to be conducted to
ascertain that the wiring circuits and connected appliances are safe for use Prior to carrying out the
tests an inspection has to be done The results of the inspectionsupervision and test have to be
presented in Form G (as in Appendix IV) and Form H (as in Appendix V)
To have the test certification as in Form H the following tests shall be conducted
i Continuity Test
ii Insulation Resistance Test
iii Polarity Test
iv Earth Electrode Resistance test and
v Residual Current Device Test
1 Continuity Test
There are 3 main types of continuity tests for the final circuits-
i Protection Conductor Continuity Test
ii Final Ring Circuit Conductor Continuity Test
iii Live and Neutral Conductor Continuity Test
a) Protection Conductor Continuity Test
bull To ascertain that all protection conductors are connected in the correct and effective manner
bull Test equipment ndash Multimeter (Ohm range) or Ohm meter
54 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
bull Test Method
1 1048766 Ensure that the main switch RCD and MCB are open circuited (switched off) and all loads
are disconnected
2 1048766 Connected the test leads as in the Figure 81 The meter reading shall be less than 1 Ω
55 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Final Ring Circuit Conductor Continuity Test
bull To ensure that all conductors around the ring circuit have continuity
bull Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
bull Test Method
1 1048766 Disconnect both the supply source live conductors from the MCB the neutral conductor
from the neutral terminals and the earth conductor from the earth terminal in the distribution
fuse box
2 1048766 Connect the test leads as in the Figure 82 (EE)
3 1048766 Repeat the procedure for (L-L) and (N-N)
4 1048766 The meter reading value shall be less than 1 ohm
56 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Live and Neutral Conductor Continuity Test
a To ensure that each conductor in the circuit has continuity
b Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
2 Test Method
1 1048766 Switch off the Main switch RCD and MCB
2 1048766 Disconnect all loads
3 1048766 Switch on all switches in the circuit
4 1048766 Disconnect the fusesfinal circuit breakers and close the circuit
5 1048766 Carry out the test as shown in Figure 83
6 1048766 The meter reading value shall be less than 1Ω
57 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
58 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
CONTINUITY TEST
Insulation Resistance Test
i Ensure that there is no leakage current between phase conductors phase and neutral conductors and
phase conductor and earth
ii Test the strength of the cable insulation
iii Test Equipment ndash Insulation Resistance Tester operating voltage is 250VDC or 500VDC
iv Test Method
1 1048766 Switch off main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
59 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
4 1048766 Carry out test as in the Table below
5 1048766 Meter reading value shall be less than 1 Megaohm
60 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
61 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Insulation resitance test
62 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
INSULATION RESISTANCE TEST BETWEEN CONDUCTORS AND OPPOSITE POLARITY
Polarity Testi Ensure that each fuse or single pole control and protection device is connected only in the phase
conductor
ii Intermediate contact of Edison screw lamp holder is connected to the phase conductor
iii Ensure that phase neutral and earth conductors at socket outlets are connected at the correct
terminals
iv Test Equipment ndash Multimeter (Ohm range) or Ohm meter
v Test Method
1 1048766 Switch off Main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in Figure 85
63 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
5 1048766 Test switches and single phase control devices at the phase conductors
6 1048766 Test socket outlet connection sources
7 1048766 Test Edison screw lamp holder connections
8 1048766 Meter reading value shall be less than 1 Ω
64 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Polarity test
65 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Earth Electrode Resistance Testi To test the earth electrode resistance
ii To ascertain the suitability of the location of the electrode
iii To ensure that the electrode is not buried within the resistance area of another electrode
iv Test equipment ndash Earth Resistance Tester
v Test method -
1 1048766 Terminal rsquoErsquo is connected to the electrode to be tested (green conductor)
2 1048766 Terminal lsquoPrsquo is connected to the potential spike (yellow conductor) at a distance of 10
meters from the earth electrode
3 1048766 Terminal lsquoCrsquo is connected to the current spike (red conductor) at a distance of 20 meters
from the earth electrode
Earth Electrode Resistance Measurement Method (Figure 86)
This test must be repeated at least three times to ensure that the reading is not affected by interacting
earthing regions
i Record the first reading (Z1) Example Z1 = 10 Ω
ii Move the voltage spike to a distance of 6 meters from the original position Record the second
reading (Z2 ) Example Z2 = 10 Ω
iii Move the voltage spike to a distance of 6 meters from the original position Record the third
reading (Z3) Example Z3 = 10 Ω
66 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Residual Current Device Testi Ensure that the residual current device (RCD) trips within the set time on the occurrence of current
leakage to earth
ii Test Equipment ndash RCD Tester RCCB Tester
iii Test Method 1
1 1048766 Use the Trip Test Button
2 1048766 Press the trip button found on the RCD to determine if it trips or otherwise This test would
not be able to determine the sensitivity of the RCD nor the time taken for it to trip
iv Test Method 2
i 1048766 Use a RCD Tester
ii This equipment is equipped with a 13A plug which can be connected to a 13A socket outlet
Select the RCD sensitivity to be the same as the sensitivity of the RCD to be tested to
determine if the RCD can trip The time to trip shall not exceed 40 mS
iii 1048766 Test method ndash
a) Position the selection switch in accordance with the sensitivity of the RCD used
Example 100 mA 01 A
b) Position the operations switch to lsquoNo Triprsquo (frac12 Rated mA = 50) connect the 3 pin plug to
the 13A socket outlet
67 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
c) Switch on the 13A socket outlet ndash ensure that the P-N and P-E lights light up
This shows that the polarity is correct (Note if both the lights as above do not light up the test cannot
be continued)
d) Press the test button ndash the reading shows less than 200 mS and simultaneously the lsquotestrsquo light lights
up and the P-N and P-E lights do not light up At that instant the RCD will not trip
e) Move the selection switch to 180o (+ve wave) ndash repeat steps (d) and (e) Move the operations
switch to lsquoTriprsquo (Rated mA = 100)
g) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200mS
h) Move the selection switch to 0o (-ve wave)
i) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
j) The above test is repeated until a near correct reading is obtained
k) Record the test results
l) Change the operations switch to lsquoFast Triprsquo and press the test button ndash RCD will trip within a
time not exceeding 40 millisecond
m) Repeat a number of times at 0o or 180o
On completion of a wiring installation a number of tests on the installation have to be conducted to
ascertain that the wiring circuits and connected appliances are safe for use Prior to carrying out the
tests an inspection has to be done the following tests shall be conducted
i Continuity Test
ii Insulation Resistance Test
iii Polarity Test
iv Earth Electrode Resistance test and
v Residual Current Device Test
821 Continuity Test
There are 3 main types of continuity tests for the final circuits-
i Protection Conductor Continuity Test
ii Final Ring Circuit Conductor Continuity Test
68 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
iii Live and Neutral Conductor Continuity Test
a) Protection Conductor Continuity Test
bull To ascertain that all protection conductors are connected in the correct and effective manner
bull Test equipment ndash Multimeter (Ohm range) or Ohm meter
bull Test Method
1 1048766 Ensure that the main switch RCD and MCB are open circuited (switched off) and all loads are
disconnected
2 1048766 Connected the test leads as in the Figure 81
3 1048766 The meter reading shall be less than 1 Ω
Final Ring Circuit Conductor Continuity Test
bull To ensure that all conductors around the ring circuit have continuity
bull Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
bull Test Method
1 1048766 Disconnect both the supply source live conductors from the MCB the neutral conductor
from the neutral terminals and the earth conductor from the earth terminal in the distribution
fuse box
2 1048766 Connect the test leads as in the Figure 82 (EE)
3 1048766 Repeat the procedure for (L-L) and (N-N)
4 1048766 The meter reading value shall be less than 1 ohm Figure 82 - Final Ring Circuit Conductor
Continuity Test Ohm Meter
Disconnect both the supply source cables from mcbfuse
Take readings at earth conductors of both sources and note resistance readings
Live and Neutral Conductor Continuity Test
1 To ensure that each conductor in the circuit has continuity
2 Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
3 Test Method
1 1048766 Switch off the Main switch RCD and MCB
2 1048766 Disconnect all loads
3 1048766 Switch on all switches in the circuit
4 1048766 Disconnect the fusesfinal circuit breakers and close the circuit
5 1048766 Carry out the test as shown in Figure 83
6 1048766 The meter reading value shall be less than 1 ohm Figure 83 - Live and Neutral
Conductor Continuity Test Ohm Meter
Insulation Resistance Test
69 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
i Ensure that there is no leakage current between phase conductors phase and neutral conductors and
phase conductor and earth
ii Test the strength of the cable insulation
iii Test Equipment ndash Insulation Resistance Tester Operating voltage is 250VDC or 500VDC
iv Test Method
1 1048766 Switch off main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in the Table below
5 1048766 Meter reading value shall be less than 1 Megaohm
Polarity Test
i Ensure that each fuse or single pole control and protection device is connected only in the phase
conductor
ii Intermediate contact of Edison screw lamp holder is connected to the phase conductor
iii Ensure that phase neutral and earth conductors at socket outlets are connected at the correct
terminals
iv Test Equipment ndash Multimeter (Ohm range) or Ohm meter
v Test Method
1 1048766 Switch off Main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in Figure 85
5 1048766 Test switches and single phase control devices at the phase conductors
6 1048766 Test socket outlet connection sources
7 1048766 Test Edison screw lamp holder connections
8 1048766 Meter reading value shall be less than 1 Ω
Earth Electrode Resistance Test
i To test the earth electrode resistance
70 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
ii To ascertain the suitability of the location of the electrode
iii To ensure that the electrode is not buried within the resistance area of another electrode
iv Test equipment ndash Earth Resistance Tester
v Test method -
1 1048766 Terminal rsquoErsquo is connected to the electrode to be tested (green conductor)
2 1048766 Terminal lsquoPrsquo is connected to the potential spike (yellow conductor) at a distance of 10
meters from the earth electrode
3 1048766 Terminal lsquoCrsquo is connected to the current spike (red conductor) at a distance of 20 meters
from the earth electrode E P C Electrode 10 meter 10 meter
Figure 86 ndash Earth Electrode Resistance Measurement Test Equipment
Earth Electrode Resistance Measurement Method (Figure 86)
This test must be repeated at least three times to ensure that the reading is not affected by interacting
earthing regions
i Record the first reading (Z1) Example Z1 = 10 Ω
ii Move the voltage spike to a distance of 6 meters from the original position Record the second
reading (Z2) Example Z2 = 10 Ω
iii Move the voltage spike to a distance of 6 meters from the original position Record the third
reading (Z3)
Example Z3 = 10 Ω
Residual Current Device Test
71 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
i Ensure that the residual current device (RCD) trips within the set time on the occurrence of current
leakage to earth
ii Test Equipment ndash RCD Tester RCCB Tester
iii Test Method 1
1 1048766 Use the Trip Test Button
2 1048766 Press the trip button found on the RCD to determine if it trips or otherwise This test would
not be able to determine the sensitivity of the RCD nor the time taken for it to trip
iv Test Method 2
1048766 Use a RCD Tester
This equipment is equipped with a 13A plug which can be connected to a 13A socket outlet Select the
RCD sensitivity to be the same as the sensitivity of the RCD to be tested to determine if the RCD can
trip The time to trip shall not exceed 40 mS
1048766 Test method ndash
a) Position the selection switch in accordance with the sensitivity of the RCD used
Example 100 mA 01 A
b) Position the operations switch to lsquoNo Triprsquo (frac12 Rated mA = 50) connect the 3 pin plug to
the 13A socket outlet
c) Switch on the 13A socket outlet ndash ensure that the P-N and P-E lights light up This shows that
the polarity is correct (Note if both the lights as above do not light up the test cannot be
continued)
d) Press the test button ndash the reading shows less than 200 millisecond and simultaneously the
lsquotestrsquo light lights up and the P-N and P-E lights do not light up At that instant the RCD will
not trip
e) Move the selection switch to 180o (+ve wave) ndash repeat steps (d) and (e) = 100)
f) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
g) Move the selection switch to 0o (-ve wave)
h) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
i) The above test is repeated until a near correct reading is obtained
j) Record the test results
k) Change the operations switch to lsquoFast Triprsquo and press the test button ndash RCD will trip within a
time not exceeding 40 mS
l) Repeat a number of times at 0o or 180o
72 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 9 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (DC)
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
73 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Start stop button 240Vac 5A 2
9 Filament lamp (Bulb ) 240Vac 40W 3
10 Overload Relay 415V 20A 3
11 Three phase induction motor 5 hp 3
12 Single phase step down transformer 2500VA 1
13 Single core PVC insulated Cable 1mm 2 As required
14 Single core PVC insulated Cable 25mm 2 As required
15 DIN rail 35 mm As required
16 PVC type Cable tray 50 mm x 50 mm As required
17 Cable ties 4 ldquo As required
18 Flexible wires 05 mm As required
19 PVC Connectors 5 A amp 20 A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the schematic
diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a optional exercise
i Simple DOL starter
ii Forward reverse DOL starter
iii Forward Reverse Dahlander motor
iv Three motors operated in sequence by DOL starter operated by manual push
button or time delay relay
74 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
a One loop per-cycle
b Continuous operation in a loop
c optional circuit design to represent the same task
v Only one out of three motors to be operated at a time (quiz)
4 Test the functionality of completed project
LESSON 10 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (AC)
75 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 1
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Lamp point 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
76 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
11 Overload Relay 415V 20A 3
12 Three phase induction
motor
5 hp 3
13 Single core PVC insulated
Cable
1mm 2 As required
14 Single core PVC insulated
Cable
25mm 2 As required
15 DIN rail 35 mm As required
16 PVC type Cable tray 50 mm x 50 mm As required
17 Cable ties 4 ldquo As required
18 Flexible wires 05 mm As required
19 PVC Connectors 5 A amp 20 A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the
schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram optional exercise
4 Simple DOL starter
5 Forward reverse DOL starter
6 Test the functionality of completed project
77 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 1
78 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
cm
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Indicating light 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
11 Overload Relay 415V 20A 3
12 Three phase induction motor 5 hp 3
13 Single phase step down
transformer
2500VA 1
14 Single core PVC insulated
Cable
1mm 2 As required
15 Single core PVC insulated
Cable
25mm 2 As required
16 DIN rail 35 mm As required
17 PVC type Cable tray 50 mm x 50 mm As required
18 Cable ties 4 ldquo As required
19 Flexible wires 05 mm As required
20 PVC Connectors 5 A amp 20 A 240 V As required
21 Single pole MCB 6A 240 V 1
22 Single pole MCB 2A 240 V 1
23 Triple pole MCB 20A 415 V 1
24 Mounting board 30 cm x 40 cm x 3
cm
1
25 Relay cw 11 pin socket 10 A 240 Vac 2
26 Time delay relay 10 A 240 Vac 3
27 Triple pole Contactor 20A 240Vac 3
28 Batten type Lamp holder 240Vac 10 A 3
29 Start stop button 240Vac 10A 2
30 Indicating light (Bulb ) 240Vac 25W 3
31 Overload Relay 415V 20A 1
32 Three phase dahlander type
induction motor
5 hp 1
33 Single phase step down
transformer
24024Vac
2500VA
1
79 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
34 Single core PVC insulated
Cable
1mm 2 As required
35 Single core PVC insulated
Cable
25mm 2 As required
36 DIN rail 35 mm As required
37 PVC type Cable tray 50 mm x 50 mm As required
38 Cable ties 4 ldquo As required
39 Flexible wires 075 mm As required
40 PVC Connectors 5 A amp 20 A 240 V As required
41 Terminal block 20A 240Vac As required
Procedures
5 Identify each component according to specification and quantity required from the schematic
diagram attached
6 Test the functionality of each component by using multi-meter or power supply whichever
applicable
7 Wire component according to circuit diagram
8 Three motors operated in sequence by DOL starter operated by manual push button or time
delay relay
a One loop per-cycle
b Continuous operation in a loop
c optional circuit design to represent the same task
d Only one out of three motors to be operated at a time (quiz)
9 Test the functionality of completed project
80 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
BASIC DESIGN INDUSTRIAL MOTOR CONTROL (SEQUENCE CONTROL)
THREE PHASE INDUCTION MOTOR OPERATED IN SEQUENCE BY DIRECT ON LINE
STARTER
LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
81 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
82 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Lcd lamp indicator 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
11 Overload Relay 415V 20A 3
12 Three phase induction motor 5 hp 3
13 Single phase step down transformer 2500VA 1
14 Single core PVC insulated Cable 1mm 2 As required
15 Single core PVC insulated Cable 25mm 2 As required
16 DIN rail 35 mm As required
17 PVC type Cable tray 50 mm x 50 mm As required
18 Cable ties 4 ldquo As required
19 Flexible wires 1 mm Oslash As required
20 PVC Terminal block 10A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the schematic
diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a optional exercise
i Forward Reverse dahlander motor
4 Test the functionality of completed project
83 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
THREE PHASE DAHLANDER TYPE INDUCTION MOTOR OPERATED FORWARD AND
REVERSE OPERATION BY DIRECT ON LINE STARTER
84 ndash 99EASYTECH ENTERPRISE
LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
Introduction
If a motors windings are connected in the star configuration any two phases will be in series across
the supply and hence the line current will be smaller(by 577) than if the windings were connected in
the delta arrangement
Hence larger-type motors with heavy starting currents are first connected in star and then when the
starting currents fall in delta This of course means that all six of the ends of the windings must be
brought to terminations outside the casing (Fig 833)
EZTECH
EZTECH ELECTRICAL INSTALLATION GUIDE
The automatic version of this starter incorporates a timing relay which automatically changes the
connections from star to delta Figs 834 and 835 show the wiring and schematic diagrams for a star
delta starter
Objectives
1 Identify component and the specification
2 Design forward reverse star delta starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
2 ndash 99EASYTECH ENTERPRISE
REV -C
LEGENDMCCB Moulded Case Circuit BreakerTOR Thermal Over Load RelayFOW-C Mains Forward ContactorREV-C Mains Reverse ContactorDC Delta ContactorSC Star ContactorS-SW Mains Selector Switch
SC
V2
W2
U2
DC
V1
W1
U1
TOR
TOR
FOW-C
30A MCCB
TOR
MAIN CIRCUIT FORWARD REVERSE STAR DELTA
RYBN S
-SW
3 PHASEINDUCTION MOTOR
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Relay 10 A 240V 3
5 Triple pole Contactor
6 cw NO NC auxiliary contact
240Vac 20 A 4
7 Overload Relay 415 V 1
8 LED indicator 240vac 5 A 4
9 Start stop button 240Vac 5A 2
10 DIN rail 35 mm As required
11 Flexible wires 1 mm As required
12 Single core PVC insulated
wire
25 mm As required
13 Terminal block 20 A As required
14 Squirrel cage motor 5kW 1
15 5 pin plug and socket 415V 20A 1
16 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
3 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
a Manual star delta
b Manual Forward reverse star delta starter
c Automatic star delta starter
d Automatic Forward reverse star delta starter
4 Test the functionality of completed project
4 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
Objectives
1 Identify component and the specification
2 Design auto transformer starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
5 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Autotransformer starter is used to start a 3 phase induction motor that has a rating between 10 to 15 hp
6 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Autotransformer set 10Kw 415 V 50 Hz 1
5 Triple pole Contactor 240Vac 4
6 Batten type Lamp holder 240 Vac 105 A 4
7 Start stop button 240Vac 10A 4
8 Filament lamp (Bulb ) 240Vac 40W 4
9 DIN rail 35 mm As required
10 Flexible wires 1 mm As required
7 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
11 Single core PVC insulated
wire
25 mm As required
12 Terminal block 20 A As required
13 Squirrel cage motor 10kW 1
14 5 pin plug and socket 415V 20A 1
15 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a open transient autotransformer starter
b close transient autotransformer starter
c Forward reverse autotransformer starter
4 Test the functionality of completed project
8 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
Objectives
1 Identify component and the specification
2 Design rotor resistance starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
9 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Rotor Resistor set 10kW 1
5 Triple pole Contactor 240Vac 20A 4
6 Indicating light 240vac 5 A 4
7 Start stop push button 240Vac 5A 4
8 DIN rail 35 mm As required
9 Flexible wires 1 mm 2 As required
10 Single core PVC insulated wire 25 mm 2 As required
11 Terminal block 20 A As required
12 Slip Ring motor 10kW 1
13 5 pin round 3 phase socket 415V 20A 1
14 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
10 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
4 Test the functionality of completed project
a Dead circuit test b Life circuit test
5 Measure starting and running Amps
LESSON 16
TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
An installation in general will suffer damage
Damage usually occurs on the electric motor control as follows
1 Damage to the main circuit
2 Damage to the control circuit
The cause of the damage
i Overcurrent overload short circuit
ii Leakage current to ground
iii Equipment malfunction
iv The main control circuit
a Trip of main circuit protection devices fire
b Defect of motor terminal such as short circuit fire loose
v The control circuit is not functioning -
a contactor relay relay time overload relay does not work damaged burned
b Loose cable connection disconnected
Detecting and Repairing Damage
Examples of damage are as follows
i Motor does not work
ii Motor function and overload relay trips
iii Motor function but only partially functional control circuit
Methods of detecting damage
Among the known methods necessary to detect damage are as follows
1 Turn off the electricity at the main switch (main switch) in order to avoid any danger during the
work carried out to detect damage
2 Check all the protective gear that controls the motor control main circuit
11 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
3 Make sure the damage function control circuit
4 Check the control circuit according to the schematic circuit diagram of the motor control
5 Check the operation of the control circuit
Note
Use wiring that has been installed on the SYSTEM OF MOTOR CONTROL BOARD by Forward
Reverse control circuit for Star Delta to test and look for damage
SELF-ASSESSMENT QUESTIONS
1 (a) Explain what is meant by the term lsquoback emfrsquo in a motor
(b) Outline the basic differences between series shunt and compound wound dc motors
2 (a) With the aid of diagrams explain how the speed of series shunt and compound-wound motors
may be controlled
(b) A 440V dc shunt-wound motor has a field resistance of 200R and an armature resistance of 06 R
When its speed is 20 rev d second the current drawn from the supply is 122A Calculate its back
emf at this speed If the speed were decreased to 19 revssecond the field flux remaining unchanged
calculate the new back emf and the new armature current
3 A load of 64 kW at 240 V is supplied from the terminals of a shunt-wound dc generator The field
resistance is 180 A Calculate the armature current
4 (a) Explain with the aid of a diagram how a rotating magnetic field may be
(b) What is meant by lsquosynchronous speedrsquo
Calculate the synchronous obtained speed of a 12 pole motor if the supply frequency is 50Hz
5 (a) Explain the action of a synchronous motor
(b) What methods are available to start a synchronous motor Explain with diagrams
6 (a) Explain the action of a cage induction motor
(b) What is meant by the term lsquosliprsquo
Calculate the percentage slip of a six pole induction motor running at 162 revssecond from a 50 Hz
supply
7 Describe with sketches three different ways of starting a single-phase induction motor
12 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
8 Explain with the aid of a sketch the action of a three-phase DOL starter
What are dashpots used for How are remote start and stop buttons connected
9 A I0 kW 240V 50Hz single-phase cage rotor induction motor is 85efficient and has a PF of 068
lagging Calculate the motor current and the value of capacitor required to raise the PF to 093
lagging
10 Calculate the torque developed by an 18 kW four-pole induction motor run at 35 slip from a
50Hz supply
APPENDIX 1
13 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 11
14 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 111
Attachment Reference
httpswwwtlc-directcoukBook621htm
httpwwwstgovmyindexphpms
15 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
The circuit breakers or fuses must be installed on the live conductors only For three phase circuits all
the circuit breakers or fuses must be combined in one set of circuits
Selection of over current devices must be based on the short circuit fault current levels of the circuit
breaker or main switch (kA)
ii Earth Leakage Current Protection
Properly rated Residual Current Devices (RCD) must be used for protection from earth leakage
currents (to prevent electric shocks)
a) Regulation 36(1) of the Electricity Regulations 1994 states that for a place of public entertainment
protection against earth leakage current must be provided by a residual current device of sensitivity
not exceeding 10 mA
b) Regulation 36(2) of the Electricity Regulations 1994 states that for a place where the floor is likely
to be wet or where the wall or enclosure is of low electrical resistance protection against earth leakage
current must be provided by a residual current device of sensitivity not exceeding 10 mA
c) Regulation 36(3) of the Electricity Regulations 1994 states that for an installation where hand-held
equipment apparatus or appliance is likely to be used protection against earth leakage current must be
provided by a residual current device of sensitivity not exceeding 30 mA and
d) Regulation 36(4) of the Electricity Regulations 1994 states that for an installation other than the
installation in (a) (b) and (c) protection against earth leakage current must be provided by a residual
current device of sensitivity not exceeding 100 mA
CABLE SELECTION
31 Selection of Wiring Cable Type
The selection of the cable size has to take into consideration the following-
i All wiring cables must be PVC or PVCPVC insulated with copper conductors Conductors with
cross sectional areas of 16mm2 or less must be of copper Aluminium conductors are not permitted
Refer to Table 4D1A in Appendix II for the current carrying capacities of copper conductor
ii Cables for swimming pools must be water resistant PE (polyethylene) insulated
10 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
iii The selected cable must be capable of delivering the electrical energy efficiently
iv The cable size allows it to carry the current without heating the cable
v The voltage drop must not exceed 4 of the supply voltage Refer to Table 4D1B in Appendix III
vi The cable insulation must be suitable for the surrounding conditions of the installation such as the
ability to withstand the surrounding temperatures and the ability to provide mechanical protection
vii Each conductor in the installation must be protected from overcurrent by means of overcurrent
protection devices needed to prevent damage to the cable insulation
32 Factors Related to Cable Current Carrying CapacityThe following factors in relation to the current carrying capacity of cables must be taken into
consideration-
i Surface wiring using clips ndash group factor
ii Wiring using conduits ndash space factor 40
iii Wiring using ducts ndash space factor 45
iv Concealed wiring ndash group factor and
v Concealed wiring using ducts ndash surrounding temperature factor
Use of Minimum Cross Sectional Area Rating of Wiring ConductorsThe following are the minimum cross sectional areas of conductors based on their applications-
Use of Protection Conductor Minimum Cross Sectional Area Rating
In Comparison with Phase Conductor Cross Sectional Area
The following table shows the protection conductor minimum cross sectional area in comparison
with the phase conductor cross sectional area
Functions and Colour Identification of Non Flexible Cables
The following table shows the functions and colour identification of non flexible cables
11 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
33 Use of Minimum Cross Sectional Area Rating of Wiring Conductors
The following are the minimum cross sectional areas of conductors based on their applications-
34 Use of Protection Conductor Minimum Cross Sectional Area Rating
In Comparison with Phase Conductor Cross Sectional Area
The following table shows the protection conductor minimum cross sectional area in comparison
with the phase conductor cross sectional area
Use of Minimum Cross Sectional Area Rating of Wiring Conductors
The following are the minimum cross sectional areas of conductors based on their applications-
Use of Protection Conductor Minimum Cross Sectional Area Rating
In Comparison with Phase Conductor Cross Sectional Area
The following table shows the protection conductor minimum cross sectional area in comparison
with the phase conductor cross sectional area
Functions and Colour Identification of Non Flexible CablesThe following table shows the functions and colour identification of non flexible cables
12 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Flexible Cables
i Flexible cables of cross sectional area less than 40 mm2 are used in installations for electrical
accessories such as ceiling roses lamp fixtures or attachments socket plugs for mobile
appliances etc
ii Flexible cables shall not be used for permanent wiring
iii Flexible cables for the permanent use of electrical appliances should not exceed 3 meters in
length
37 Functions and Colour Identification of Flexible Cables
Conductor Insulation and Types of WiringVarious material and insulation layers are used for conductor protection Cable selection in
accordance to insulation layers must be done correctly for the type of the wiring installation as
shown in the table below
Functions and Colour Identification of Non Flexible CablesThe following table shows the functions and colour identification of non flexible cables
3 SELECTION OF WIRING ACCESSORIES
i All wiring accessories to be used have to be of those approved by the Energy Commission and
labeled with labels issued by SIRIM For all wiring using UPVC conduits -
13 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
a) Switches socket outlets 3 pin plugs ceiling roses connectors sockets ndash construction material shall
be of polycarbonate type
iii For all wiring using metal conduits - Switches socket outlets and connectors ndash construction
material shall be of metal clad type and All accessories shall be effectively earthed
iv Switch fuse used in single phase installations shall have the fuse permanently connected and not
move with the fuse
v Fuse switch used in 3 phase domestic installations also has fuse and switch The fuse connector is
installed together to allow the fuse to move simultaneously with the switch
vi Lamp
a) Fluorescent lamps using magnetic ballasts (watt loss not exceeding 6 watts) shall be
equipped with dry paper type capacitor
b) Fluorescent lamps using electronic ballasts or high frequency electronic ballasts do not
need capacitors
c) Outdoor domestic lamp installations shall use weather proof and water proof lamps
d) Submerged light installations (example in swimming pools fountains etc) shall have water
proof lamps with a voltage not exceeding 12 Volt AC
vii Electric water heaters is divided into 2 types namely
1 instantaneous water heaters and
2 stored water heaters (storage tank type)
a) Instantaneous water heaters shall be equipped with a 2 pole control switch and its own
residual current device
b) Storage water heaters (storage tank type) shall be installed with an
Water heaters exceeding 3kW shall be permanently connected to a 20A30A rated circuit
breakerfuse with an isolator switch and residual current device
viii Electric cookers exceeding 3kW shall have its own circuit connected permanently to a 30A rated
circuit breaker or fuse with an isolator switch and cooker control unit incorporated with a 13A socket
outlet Two or more cooker appliances may be installed in the same room within a distance of 2
meters
ix Electric motors (fence gate air conditioners fountains swimming pools fish ponds water
pumps) exceeding 373W but not exceeding 2238W shall be connected permanently to a 20A30A
rated circuit breakerfuse together with an isolator motor starter and 15A socket outlet
14 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
The motor starter shall be of Direct-On-Line type with the appliance together with the contactor
overload relay and on-off control The circuit breakerfuse which controls the motor circuit shall be
capable of withstanding the starting current of the motor
x Electric bells ndash the circuit shall have a push button switch and a ACDC transformer
xi Ceiling fans shall conform to clause 21101 of the MS 12192002 standard with regards to test on
the suspension system of ceiling fans
EARTHING OF ELECTRICAL INSTALLATIONS51 Earthing
Earthing is a connection system between the metallic parts of an electrical wiring system and the
general mass of the earth This will provide an easy path with a low impedence or resistance to earth to
enable the protection system to operate effectively It will thus ensure safety to human
beingsconsumers from the dangers of electric shocks if earth leakage currents are present In general
an electrical installation is earthed because of -
i Safety reasons
ii Protection system requirements
iii Need to limit over voltages
iv Need to provide a path for electrical discharge
v Legal requirements
52 Classification of Earthing
Generally earthing can be divided into 2 parts namely -
i System Earthing
a To isolate the system under fault conditions
b To limit the potential difference between conductors which are not insulated in an area
c To limit the occurrence of over voltages under various conditions
ii Equipment Earthing
Equipment earthing is undertaken to protect human beingsconsumers If a live source comes into
contact with the equipment body electrical energy will flow to the earth without flowing through the
human being consumerrsquos body This is because of the fact that the human body has a greater
resistance compared with the resistance to earth
53 Types and Functions of Earthing Accessories
Earthing accessories are as follows -
i Earthing Electrode
Copper jacketed steel core rods are used as electrodes for domestic wiring
ii Equipotential Bonding
15 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
This is the conductor which is connected between the consumer earthing point and the exposed
metallic part The minimum cable size for this purpose is 10 mm2
iii Protection Conductor
This is the conductor which connects the consumer earthing point with other parts of the installation
which needs earthing Its size is as follows-
a) Same size as the phase cable up to a size of 16mm2
b) 16 mm2 if the phase cable size is between 16 mm2 and 35 mm2
c) Half the size of the phase cable if the size of the phase cable exceeds 35 mm2
54 Earthing Arrangements Using a TT System
i The first alphabet indicates the earthing arrangements from the supply side
ii The second alphabet indicates the earthing arrangement in the consumerrsquos installation
T ndash first Indicates that the supply system has its own earthing arrangements
T ndash second Indicates that all metallic frames of the electrical appliances etc are connected directly to
earth
Parts that are Required to be Earthed
i All metallic structures in the wiring system (non current carrying) such as metallic covers conduits
ducts the armour of catenary wires etc
ii A secondary winding point in a transformer and
iii Frame of metal roof truss
56 Parts that are not Required to be Earthed
i Short isolated metallic parts for mechanical protection of cables which have non metallic sheaths
other than conduits which are connected at entry points between the building and conduits which
protect discharge lamp cables
ii Cable clips for installing cables
iii Metallic covers for lamps
16 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
iv Small metallic parts such as screws and name plates which are isolated by means of insulation
v Metallic lamp parts for filament lamps in water proof floors
57 Termination to Earth
The termination to earth is done as shown in Figure 72
Earth Electrode Resistance
The maximum permitted earth electrode resistance for different types of installations is as shown in
the Table below
Earth electrode for installations protected by RCDs of sensitivity 100mA 10 Ω
Lightning arrestor earth electrode 10 Ω
Legal Requirements
i Sub regulation 12(1) and 12(2) of the Electricity Regulations 1994 state that any electrical wiring in
an installation shall be under the immediate supervision of a Wireman with Single Phase Restriction or
Three Phase Restriction Upon completion the Wireman shall certify a Supervision and Completion
Certificate
ii Sub regulation 13(1) and 13 (2) of the Electricity Regulations 1994 state that the installation shall
be tested by a Wireman with Single Phase Restriction or a Wireman with Three Phase Restriction
authorized to test any installation and who shall certify a Test Certificate for the installation
iii Sub regulation 14(1) of the Electricity Regulations 1994 states that the Supervision and
Completion Certificate and the Test Certificate as in regulations 12 and 13 shall be in Forms G and H
respectively as prescribed in the First Schedule
17 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
4 SAFETY REQUIREMENTS FOR ELECTRICAL WIRING WORKS IN RESIDENTIAL BUILDINGS
61 Safety Requirements
Safety requirements for electrical wiring works have to be followed to eliminate any accidents which
can result in physical damage or loss of life or property Failure to meet the safety regulations may
result in workers consumers or the public being inflicted with electrical shocks
In addition to this safety steps will also encourage workers or electricity consumers who are
disciplined and who always give importance to safety
62 Safety Steps
Safety requirements have to be followed whenever electrical works are undertaken in a residential
building
i Personal Safety
a Use suitable personal protection equipment as needed such as safety shoes gloves safety helmet
etc when at the work place
b Use safety clothing suitable for the work to be undertaken
c Do not wear jewellery or decorative items such as rings watches chains etc while carrying out
electrical works
ii Safety at the Work Place
a Acquire knowledge about the dangers of electrical works that is to be undertaken and how to deal
with those dangers
b Always adhere to the safety regulations which have been set for the work place
c Ensure that the electricity supply is switched off before carrying out the works
d Acquire the needed knowledge and practice a cautious and calm attitude while working ensure
cleanliness in and around fellow workers
e While working at elevated places the worker should always use suitable equipment such as wooden
or aluminium ladders iron scaffoldings or platforms safety belts or other equipment needed to ensure
that the work can be undertaken safely
f Use electrical equipment which is operational and safe to be used and ensure that the supply for it is
being supplied through a residual current device (RCD) with a sensitivity of 30 mA
g Ensure that exposed temporary supply electrical cables have mechanical protection
h If inflammable or corrosive material is present necessary safety steps have to be undertaken as
required by the relevant safety regulations
63 Dangers of Electrical Shocks
i Electrical Shock
Electrical shocks can occur due to direct or indirect contact
a Direct Contact
18 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Direct contact occurs when the worker or consumer receives an electrical shock on touching directly a
live conductor or cable
b Indirect Contact
Here the electric shock occurs due to contact with a part which is connected to the electrical
installation and not to a direct contact with a live cable or conductor possibly due to damages in the
appliance or insulation resulting in leakages of current
Why Electric Shocks Occura Unsafe Work Method or Action Undertaking Electrical Work Without Disconnecting the
Supply
Maintenance or circuit testing work done without disconnecting the supply will have a high possibility
of electrical shocks occurring
bull Not Following Safe Work Procedures
To eliminate the occurrence of electrical shocks each worker has to always follow safe work
procedures which are set by regulations and standards
b Defects in the Electrical System
i Leakage Current
Leakage currents or earth leakage currents can result in the metallic frames becoming live and
energised This can give rise to the danger of electrical shock to the worker consumer or the public if
they hold or come into contact with the metallic frame
ii Exposed Conductor or Disconnected Cable
Exposed conductors or cables which are broken and are alive (energised) can result in electrical shock
when touched The supply source must be immediately isolated or switched off and a report must be
made to the responsible entity
64 First Aid and Basic Pulmonary Resuscitation
i First Aid
First aid is the initial assistance given to a person who has met with an accident is sick or is injured to
prevent the condition of the victim from becoming more serious while awaiting the arrival of the
paramedics (ambulance) or before being brought to the hospital
i Pulmonary Resuscitation
Pulmonary resuscitation has to be undertaken to assist the victim who has breathing difficulties as a
result of being drowned receiving an electrical shock etc Pulmonary resuscitation has to be carried
out in accordance to the correct method as stated in the first aid manuals issued by accredited first aid
bodies
ii First Aid Box
19 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
A first aid box has to be provided by the building owner construction site supervisor or brought
personally by the worker under the supervision of the responsible person
65 Training Programme
The management shall conduct periodic training programmes for the workers with regards to work
safety on aspects including the following -
i Dangers of electrical work being undertaken and how to control those dangers
ii The safety regulations set for the work place and
iii First aid procedures
66 Fire Prevention
Fire Extinguisher A suitable functioning fire extinguisher to control fires has to be made available at
the work place at all times
67 Competent Person
The Electricity Regulations 1994 require that all electrical work has to be undertaken by or under the
direct supervision of a competent person registered with the Energy Commission Besides that the
electrical contractor undertaking the electrical work has also to be registered with the Energy
Commission The installation owner thus has to ensure that the appointed electrical contractor is
registered with the Energy Commission and that the registration is still valid
INSTALLATION CIRCUITS AND SYSTEMS1 Block diagrams
These show using squares rectangles etc the sequence of a system without too much technical detail
eg Figures 1517 and 1526
2 Layout diagrams
These are very similar to block diagrams but they indicate more technical detail and tend to show
items in their correct geographical location (eg Figures 1518 and 1519)
3 Circuitschematic
These show how a circuit functions and takes no account of exact locations of terminals or equipment
(eg Figures 1528 1529 1532 1534 etc)
4 Wiring diagram
These indicate how a circuit or system is physically wired (eg Figures 152 154 156 etc)
Most induction motors are started directly on line but when very large motors are started that way
they cause a disturbance of voltage on the supply lines due to large starting current surges To limit the
starting current surge large induction motors are started at reduced voltage and then have full supply
voltage reconnected when they run up to near rotated speed Two methods are used for reduction of
starting voltage are star delta starting and auto transformer stating
20 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Working Principal of Star-Delta Starter
This is the reduced voltage starting method Voltage reduction during star-delta starting is achieved by
physically reconfiguring the motor windings as illustrated in the figure below During starting the
motor windings are connected in star configuration and this reduces the voltage across each winding 3
This also reduces the torque by a factor of three After a period of time the winding are reconfigured as
delta and the motor runs normally
StarDelta starters are probably the most common reduced voltage starters They are used in
an attempt to reduce the start current applied to the motor during start as a means of reducing the
disturbances and interference on the electrical supply
Traditionally in many supply regions there has been a requirement to fit a reduced voltage
starter on all motors greater than 5HP (4KW) The StarDelta (or WyeDelta) starter is one of the
lowest cost electromechanical reduced voltage starters that can be applied
The StarDelta starter is manufactured from three contactors a timer and a thermal overload
The contactors are smaller than the single contactor used in a Direct on Line starter as they are
controlling winding currents only The currents through the winding are 1root 3 (58) of the
current in the line
There are two contactors that are close during run often referred to as the main contractor and
the delta contactor These are AC3 rated at 58 of the current rating of the motor The third
contactor is the star contactor and that only carries star current while the motor is connected in star
The current in star is one third of the current in delta so this contactor can be AC3 rated at one
third (33) of the motor rating
Star-delta Starter Consists following units
1) Contactors (Main star and delta contactors) 3 Norsquos (For Open State Starter) or 4 Norsquos (Close
Transient Starter)
2) Time relay (pull-in delayed) 1 No
3) Three-pole thermal over current release 1No
4) Fuse elements or automatic cut-outs for the main circuit 3 Nos
5) Fuse element or automatic cut-out for the control circuit 1No
Power Circuit of Star Delta Starter
1 The main circuit breaker serves as the main power supply switch that supplies electricity to the
power circuit
2 The main contactor connects the reference source voltage R Y B to the primary terminal of the
motor U1 V1 W1
21 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
3 In operation the Main Contactor (KM3) and the Star Contactor (KM1) are closed initially and
then after a period of time the star contactor is opened and then the delta contactor (KM2) is
closed The control of the contactors is by the timer (K1T) built into the starter The Star and Delta
are electrically interlocked and preferably mechanically interlocked as well In effect there are
four states
4 The star contactor serves to initially short the secondary terminal of the motor U2 V2 W2 for the
start sequence during the initial run of the motor from standstill This provides one third of DOL
current to the motor thus reducing the high inrush current inherent with large capacity motors at
startup
5 Controlling the interchanging star connection and delta connection of an AC induction motor is
achieved by means of a star delta or wye delta control circuit The control circuit consists of push
button switches auxiliary contacts and a timer
Control Circuit of Star-Delta Starter (Open Transition)
1 The ON push button starts the circuit by initially energizing Star Contactor Coil (KM1) of star
circuit and Timer Coil (KT) circuit
2 When Star Contactor Coil (KM1) energized Star Main and Auxiliary contactor change its
position from NO to NC
3 When Star Auxiliary Contactor (1)( which is placed on Main Contactor coil circuit )became
NO to NC itrsquos complete The Circuit of Main contactor Coil (KM3) so Main Contactor Coil
energized and Main Contactorrsquos Main and Auxiliary Contactor Change its Position from NO
To NC This sequence happens in a friction of time
4 After pushing the ON push button switch the auxiliary contact of the main contactor coil (2)
which is connected in parallel across the ON push button will become NO to NC thereby
providing a latch to hold the main contactor coil activated which eventually maintains the
control circuit active even after releasing the ON push button switch
5 When Star Main Contactor (KM1) close its connect Motor connects on STAR and itrsquos
connected in STAR until Time Delay Auxiliary contact KT (3) become NC to NO
6 Once the time delay is reached its specified Time the timerrsquos auxiliary contacts (KT)(3) in
Star Coil circuit will change its position from NC to NO and at the Same Time Auxiliary
contactor (KT) in Delta Coil Circuit(4) change its Position from NO To NC so Delta coil
energized and Delta Main Contactor becomes NO To NC Now Motor terminal connection
change from star to delta connection
7 A normally close auxiliary contact from both star and delta contactors (5amp6)are also placed
opposite of both star and delta contactor coils these interlock contacts serves as safety
switches to prevent simultaneous activation of both star and delta contactor coils so that one
22 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
cannot be activated without the other deactivated first Thus the delta contactor coil cannot be
active when the star contactor coil is active and similarly the star contactor coil cannot also
be active while the delta contactor coil is active
8 The control circuit above also provides two interrupting contacts to shutdown the motor
The OFF push button switch break the control circuit and the motor when necessary The
thermal overload contact is a protective device which automatically opens the STOP Control
circuit in case when motor overload current is detected by the thermal overload relay this is to
prevent burning of the motor in case of excessive load beyond the rated capacity of the motor
is detected by the thermal overload relay
9 At some point during starting it is necessary to change from a star connected winding to a
delta connected winding Power and control circuits can be arranged to this in one of two
ways ndash open transition or closed transition
What is Open or Closed Transition Starting
(1) Open Transition Starters
Discuss mention above is called open transition switching because there is an open state between
the star state and the delta state
In open transition the power is disconnected from the motor while the winding are reconfigured via
external switching
When a motor is driven by the supply either at full speed or at part speed there is a rotating
magnetic field in the stator This field is rotating at line frequency The flux from the stator field
induces a current in the rotor and this in turn results in a rotor magnetic field
When the motor is disconnected from the supply (open transition) there is a spinning rotor within
the stator and the rotor has a magnetic field Due to the low impedance of the rotor circuit the time
constant is quite long and the action of the spinning rotor field within the stator is that of a
generator which generates voltage at a frequency determined by the speed of the rotor When the
motor is reconnected to the supply it is reclosing onto an unsynchronized generator and this result
in a very high current and torque transient The magnitude of the transient is dependent on the
phase relationship between the generated voltage and the line voltage at the point of closure can
be much higher than DOL current and torque and can result in electrical and mechanical damage
Open transition starting is the easiest to implement in terms or cost and circuitry and if the timing
of the changeover is good this method can work well In practice though it is difficult to set the
necessary timing to operate correctly and disconnectionreconnection of the supply can cause
significant voltagecurrent transients
In Open transition there are Four states
23 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 OFF State All Contactors are open
2 Star State The Main [KM3] and the Star [KM1] contactors are closed and the delta [KM2]
contactor is open The motor is connected in star and will produce one third of DOL torque at one
third of DOL current
3 Open State This type of operation is called open transition switching because there is an
open state between the star state and the delta state The Main contractor is closed and the Delta
and Star contactors are open There is voltage on one end of the motor windings but the other end
is open so no current can flow The motor has a spinning rotor and behaves like a generator
4 Delta State The Main and the Delta contactors are closed The Star contactor is open The
motor is connected to full line voltage and full power and torque are available
(2) Closed Transition StarDelta Starter
There is a technique to reduce the magnitude of the switching transients This requires the use of a
fourth contactor and a set of three resistors The resistors must be sized such that considerable
current is able to flow in the motor windings while they are in circuit
The auxiliary contactor and resistors are connected across the delta contactor In operation just
before the star contactor opens the auxiliary contactor closes resulting in current flow via the
resistors into the star connection Once the star contactor opens current is able to flow round
through the motor windings to the supply via the resistors These resistors are then shorted by the
delta contactor If the resistance of the resistors is too high they will not swamp the voltage
generated by the motor and will serve no purpose
In closed transition the power is maintained to the motor at all time This is achieved by
introducing resistors to take up the current flow during the winding changeover A fourth
contractor is required to place the resistor in circuit before opening the star contactor and then
removing the resistors once the delta contactor is closed These resistors need to be sized to carry
the motor current In addition to requiring more switching devices the control circuit is more
complicated due to the need to carry out resistor switching
In Close transition there are Four states
1 OFF State All Contactors are open
2 Star State The Main [KM3] and the Star [KM1] contactors are closed and the delta [KM2]
contactor is open The motor is connected in star and will produce one third of DOL torque at one
third of DOL current
Star Transition State The motor is connected in star and the resistors are connected across the
delta contactor via the aux [KM4] contactor
24 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Closed Transition State The Main [KM3] contactor is closed and the Delta [KM2] and Star
[KM1] contactors are open Current flows through the motor windings and the transition resistors
via KM4
Delta State The Main and the Delta contactors are closed The transition resistors are shorted out
The Star contactor is open The motor is connected to full line voltage and full power and torque
are available
Effect of Transient in Starter (Open Transient starter)
It is Important the pause between star contactor switch off and Delta contactor switch is on correct
This is because Star contactor must be reliably disconnected before Delta contactor is activated It
is also important that the switch over pause is not too long
For 415v Star Connection voltage is effectively reduced to 58 or 240v The equivalent of 33
that is obtained with Direct Online (DOL) starting
If Star connection has sufficient torque to run up to 75 or 80 of full load speed then the motor
can be connected in Delta mode
When connected to Delta configuration the phase voltage increases by a ratio of V3 or 173 The
phase currents increase by the same ratio The line current increases three times its value in star
connection
During transition period of switchover the motor must be free running with little deceleration
While this is happening ldquoCoastingrdquo it may generate a voltage of its own and on connection to the
supply this voltage can randomly add to or subtract from the applied line voltage This is known as
transient current Only lasting a few milliseconds it causes voltage surges and spikes Known as
a changeover transient
Size of each part of Star-Delta starter
(1) Size of Over Load Relay
For a star-delta starter there is a possibility to place the overload protection in two positions in the
line or in the windings
Overload Relay in Line
In the line is the same as just putting the overload before the motor as with a DOL starter
The rating of Overload (In Line) = FLC of Motor
Disadvantage If the overload is set to FLC then it is not protecting the motor while it is in delta
(setting is x1732 too high)
Overload Relay in Winding
25 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
In the windings means that the overload is placed after the point where the wiring to the contactors
are split into main and delta The overload then always measures the current inside the windings
The setting of Overload Relay (In Winding) =058 X FLC (line current)
Disadvantage We must use separate short circuit and overload protections
(2) Size of Main and Delta Contractor
1 There are two contactors that are close during run often referred to as the main contractor and
the delta contactor These are AC3 rated at 58 of the current rating of the motor
Size of Main Contactor= IFL x 058
(3) Size of Star Contractor
The third contactor is the star contactor and that only carries star current while the motor is
connected in star The current in star is 1 radic3= (58) of the current in delta so this contactor can
be AC3 rated at one third (33) of the motor rating
Size of Star Contactor= IFL x 033
Motor Starting Characteristics of Star-Delta Starter
Available starting current 33 Full Load Current
Peak starting current 13 to 26 Full Load Current
Peak starting torque 33 Full Load Torque
Advantages of Star-Delta starter
The operation of the star-delta method is simple and rugged
It is relatively cheap compared to other reduced voltage methods
Good TorqueCurrent Performance
It draws 2 times starting current of the full load ampere of the motor connected
Disadvantages of Star-Delta starter
Low Starting Torque (Torque = (Square of Voltage) is also reduce)
Break In Supply ndash Possible Transients
Six Terminal Motor Required (Delta Connected)
It requires 2 set of cables from starter to motor
It provides only 33 starting torque and if the load connected to the subject motor requires higher
starting torque at the time of starting than very heavy transients and stresses are produced while
changing from star to delta connections and because of these transients and stresses many
electrical and mechanical break-down occurs
26 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
In this method of starting initially motor is connected in star and then after change over the motor
is connected in delta The delta of motor is formed in starter and not on motor terminals
High transmission and current peaks When starting up pumps and fans for example the load
torque is low at the beginning of the start and increases with the square of the speed When
reaching approx 80-85 of the motor rated speed the load torque is equal to the motor torque and
the acceleration ceases To reach the rated speed a switch over to delta position is necessary and
this will very often result in high transmission and current peaks In some cases the current peak
can reach a value that is even bigger than for a DOL start
Applications with a load torque higher than 50 of the motor rated torque will not be able to start
using the start-delta starter
Low Starting Torque The star-delta (wye-delta) starting method controls whether the lead
connections from the motor are configured in a star or delta electrical connection The initial
connection should be in the star pattern that results in a reduction of the line voltage by a factor of
1radic3 (577) to the motor and the current is reduced to 13 of the current at full voltage but the
starting torque is also reduced 13 to 15 of the DOL starting torque
The transition from star to delta transition usually occurs once nominal speed is reached but is
sometimes performed as low as 50 of nominal speed which make transient Sparks
Features of star-delta starting
1 For low- to high-power three-phase motors
2 Reduced starting current
3 Six connection cables
4 Reduced starting torque
5 Current peak on changeover from star to delta
6 Mechanical load on changeover from star to delta
Application of Star-Delta Starter
The star-delta method is usually only applied to low to medium voltage and light starting
Torque motors
The received starting current is about 30 of the starting current during direct on line start and the
starting torque is reduced to about 25 of the torque available at a DOL start This starting
method only works when the application is light loaded during the start If the motor is too heavily
27 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
loaded there will not be enough torque to accelerate the motor up to speed before switching over
to the delta position
LESSON 1 WIRING SYSTEM OF SINGLE PHASE DISTRIBUTION BOARD
Introduction
28 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
29 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
30 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
31 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 2 WIRING SYSTEM OF SINGLE PHASE LIGHTING CIRCUIT Introduction
Objectives
1 Identify component and the specification
2 Wire component according to the schematic diagram
3 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Wiring bay Perforated metal 180 cm x 180 cm 1
2 Cut out fuse 63 A 240 V 1
3 Neutral link 1
4 Single pole one way switch cw
switch box
5A 240Vac 4
5 single pole two way switch cw
switch box
5A 240Vac 2
6 RCCB In = 40 A Tripping current
100mA240 Vac 50 Hz
1
7 Main switch 32 A 240V 1
8 kWatthour meter 40 A 240 Vac 1
9 Single pole MCB 6A 240 Vac 1
10 Self tapping Wood screw As required
11 DIN rail 35 mm width As required
32 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
12 PVC trunking 50 mm x 50 mm As required
13 Terminal blocks 5 A As required
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
1 One way switch to control one lamp
2 One way switch to control two lamps
3 Two of two way switch to control one lamp
4 Two of single pole two way switch and one of an intermediate switch to control one
lamp
5 One unit of ceiling fan and fan regulator to be controlled by one way switch
4 Test the functionality of completed project
LESSON 3ndash WIRING SYSTEM OF SINGLE PHASE POWER CIRCUIT Introduction
33 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
34 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify types of component and its specification
2 Wire component according to the schematic diagram given
3 Test the functionality of the circuit dead circuit test life circuit test
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board Perforated Metal 1
2 kWh meter 240 V 40 A 1
3 Socket outlet 13A 240Vac 4
4 RCCB 40A Trip Amps
30mA240 Vac
1
5 3 pin socket 240Vac 13A 4
6 Single pole MCB 20A 240 V 2
7 DOL starter 1 kW 240Vac 2
8 1 phase induction motor 2Hp 240 Vac 1
9 Cooker control unit 4kW 240Vac 1
10 Water heater point 4kW 240 Vac 1
11 DIN rail 35 mm As required
12 PVC casing 20mm As required
13 Flexible wires 05 mm As required
14 Terminal block 10 A As required
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Wire two unit of 13 A socket outlet in radial circuit
3 Wire four units of 13 A socket outlet in ring circuit
4 Wire one unit DOL starter for air-conditioner point
5 Wire one unit of cooker control unit point
6 Wire one unit of water heater point
7 Test the functionality of each component by using mmeter or power supply whichever
applicable
8 Wire component according to circuit diagram
9 Test the functionality of completed project dead circuit test life circuit test
Note
35 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Ensure that the correct rating of protection device and size of wire used
LESSON 4ndash CONDUIT BENDING AND TRUNKING FABRICATION TECHNIQUE
Common fitting used in an industrial wiring
Cutting and threading the condute
36 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
37 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
38 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify conduit fitting and the specification
2 Measure and Cut steel conduit according to specified dimension
3 Bend and fabricate conduit at 45 90 according to layout diagram
4 Wire component according to the schematic diagram
5 Test the functionality of the circuit
39 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Conduit Bender Oslash 19 mm ( frac34 ldquo) 1
2 Measuring Tape 3 metre 1
3 Hacksaw frame and blade 30cm 1
4 Conduit cutter 1
5 Pipe Vise 1
6 Pipe Wrench 1
7 Ratchet Dies 20 mm 1
8 Metal trunking 50 mm x 50 mm 1
9 GI conduit 20mm 1
10 End box 20 mm 1
11 Flexible wires 05 mm As required
12 Connectors 5 A As required
13 Single core PVC ins Cable 25 mm 2 As required
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Wire two unit of 13 A socket outlet in radial circuit
3 Wire four unit of 13 A socket outlet in ring circuit
4 Wire one unit DOL starter for air-conditioner point
5 Wire one unit of cooker control unit point
6 Wire one unit of water heater point
7 Test the functionality of each component by using multimeter or power supply whichever
applicable
8 Wire component according to circuit diagram
9 Test the functionality of completed project
Note
Ensure that the rating of protection device and size of wire
K prior to 31 March
2004 (BS 7671)
(formerly)
bare conductor
sleeved at terminations (formerly)
40 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 5 ndashWIRING SYSTEM OF 1 Oslash LIGHTING AND POWER CIRCUIT
POWER CIRCUITSa Radial circuits
Radial circuits are arranged in the same way as item 1 above in lighting layouts in that each socket
outlet is supplied via the previous one
Points to note
1 The number of socket outlets complying with BS 1363 is unlimited for a floor area of up to 50m 2 if
the circuit protection is a 30 A or 32 A cartridge fuse or circuit breaker the cable being 4 mm PVC
copper or 25 mm2 mineral insulated (mi)
2 The number of socket outlets is unlimited for a floor area up to 20 m 2 with any type of circuit
protection of 20 A using 25 mm2 PVC copper cable or 15 mm2 mi
3 The total number of fused spurs is unlimited
b ring final circuits
These circuits are the same as radial circuits except that the final socket outlet is wired back to the
supply position In effect any outlet is supplied from two directions (Fig 152)
Points to note
1 Every twin-socket outlet counts as two single-socket outlets
2 The number of non-fused spurs must not exceed the total number of points on the ring Fig 158
shows seven points on the ring and five spurs
3 The fuse rating of a fused spur box must not exceed 13 A and the current rating of all points supplied
by the fused spur must not exceed 13 A
4 Non-fused spurs must supply no more than one single or one double socket on the ring Fig 158
shows seven points on the ring and five spurs rating of all points supplied by the fused spur must not
exceed 13 A or one stationary appliance
CapacityMain conductor size
copper (mm2)
Earth conductor
size (mm2)
Circuit breaker
capacity (A)
Up to 600 W 15 15 6
600ndash1200 W 1525 15 10
1200ndash1800 W 254 25 16
41 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Ring circuit
(floor area 100 m2)25 15 3032
A2 radial circuit
(floor area 75 m2)40 25 3032
A3 radial circuit
(floor area 50 m2)25 15 20
Air conditioner (15 tonne) 60 60 3032
Cooker 60 60 3032
Water heater 40 40 20
Objectives
1 Identify component and the specification
2 Wire component according to the schematic diagram
3 Test the functionality of the circuit
42 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board Perforated 1
2 Cut out fuse and neutral link 60A 240V 1each
3 kWh meter 240V 40A 1
4 Switched Socket outlet 13A 240Vac 4
5 Single pole two way switch cw switch
box
5A 240Vac 2
6 RCCB ELCB 63 A Tripping current 100mA
415 Vac
1
7 3 pin plug 240Vac 13A 4
8 Single pole MCB 20 A 2
9 Single pole MCB 6A 1
10 Single pole MCB 20A 2
11 DOL starter 240Vac 2
12 1 phase induction motor 2hp 240 Vac 1
13 Self tapping Wood screw As required
14 DIN rail Stainless steel allum35 mm As required
15 PVC pipe 20mm dia As required
16 End box 20 mm dia 4
17 Flexible wires 05 mm 2 As required
18 Connectors 5 A As required
Procedures
43 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
4 Test the functionality of completed project
LESSON 6 ndash WIRING SYSTEM OF 3 Oslash DISTRIBUTION BOARD
Introduction
44 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
45 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
46 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
47 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
48 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify each component and the specification
2 Wire component according to the schematic diagram given
3 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting Board 450 x 600 mm Perforated metal 1
2 5 pin round socket and plug 415V ac 32A 1
3 Cut out fuse 60 A 3
4 Neutral link 1
5 kWatt hour meter 415V 60A 1
6 ELCB RCCB 3P+N In=63A415 Vac I trip= 300mA 1
7 ELCB RCCB 3P+N In=63A415 Vac I trip= 30mA 1
8 Single pole MCB 6A 240 V 3
9 Single pole MCB 20A 240 V 3
10 DOL starter 20 A 240Vac 2
11 Socket outlet 15 A 240 Vac 1
12 Switched Socket outlet 13 A 240 Vac 3
13 Led indicating light 5A 240 Vac 3
14 Single pole 4 gang 1 way switch 5A 240 Vac 2
15 Single pole 2 way switch 5A 240 Vac 2
16 1 phase induction motor 1 kW 240Vac 1
17 Metal trunking 30 mm x30 mm As required
18 Self tapping Wood screw 4 mm x 20 mm As required
19 DIN rail 25 mm x 1mm
20 GI steel rigid conduit 20mm As required
21 Flexible conduit 20mm As required
22 End box 20 mm 4
23 Flexible wires 05 mm 2 As required
24 Single core PVC insulated wire 15 mm 2 As required
25 Single core PVC insulated wires 25 mm 2 As required
26 Terminal block 10 A As required
Procedures
49 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify each components and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
4 Test the functionality of completed project
1 dead circuit test
2 life circuit
Note Proper earthing should be made
50 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 7 ndash WIRING SYSTEM OF THREE PHASE LIGHTING AND POWER CIRCUIT
51 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
52 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify component and the specification
2 Wire component according to the schematic diagram
3 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting bay Board Perforated metal 180 cm x 180 cm 1
2 k Watt hour meter 415V 60A 1
3 MCCB 415V 60A
4 ELCB RCCB In=60A415 Vac I trip=30mA 1
5 5 pin round Socket and
plug
415Vac 32A 4
6 Single pole MCB 6A 1
7 Triple pole MCB 20A 2
8 Triple pole Main switch 60A 1
9 DOL starter 240Vac 2
10 3 phase induction motor 2hp 415 Vac 1
11 1 phase induction motor 1
12 Metal trunking 30 mm x30 mm As required
13 Self tapping Wood screw 4 mm x 20 mm As required
14 DIN rail 25 mm x 1mm
15 GI steel rigid conduit 20mm As required
16 Flexible conduit 20mm As required
17 End box 20 mm 4
18 Flexible wires 05 mm As required
19 Connectors 10 A As required
Procedures
1 Identify each components and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
4 Test the functionality of completed project
1 dead circuit 2 life circuit test
5 Record the current drawn by the load as connected in star and delta
Note Proper earthing should be made
53 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 8 INSPECTION AND TESTING OF ELECTRICAL INSTALLATION
On completion of a wiring installation a number of tests on the installation have to be conducted to
ascertain that the wiring circuits and connected appliances are safe for use Prior to carrying out the
tests an inspection has to be done The results of the inspectionsupervision and test have to be
presented in Form G (as in Appendix IV) and Form H (as in Appendix V)
To have the test certification as in Form H the following tests shall be conducted
i Continuity Test
ii Insulation Resistance Test
iii Polarity Test
iv Earth Electrode Resistance test and
v Residual Current Device Test
1 Continuity Test
There are 3 main types of continuity tests for the final circuits-
i Protection Conductor Continuity Test
ii Final Ring Circuit Conductor Continuity Test
iii Live and Neutral Conductor Continuity Test
a) Protection Conductor Continuity Test
bull To ascertain that all protection conductors are connected in the correct and effective manner
bull Test equipment ndash Multimeter (Ohm range) or Ohm meter
54 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
bull Test Method
1 1048766 Ensure that the main switch RCD and MCB are open circuited (switched off) and all loads
are disconnected
2 1048766 Connected the test leads as in the Figure 81 The meter reading shall be less than 1 Ω
55 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Final Ring Circuit Conductor Continuity Test
bull To ensure that all conductors around the ring circuit have continuity
bull Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
bull Test Method
1 1048766 Disconnect both the supply source live conductors from the MCB the neutral conductor
from the neutral terminals and the earth conductor from the earth terminal in the distribution
fuse box
2 1048766 Connect the test leads as in the Figure 82 (EE)
3 1048766 Repeat the procedure for (L-L) and (N-N)
4 1048766 The meter reading value shall be less than 1 ohm
56 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Live and Neutral Conductor Continuity Test
a To ensure that each conductor in the circuit has continuity
b Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
2 Test Method
1 1048766 Switch off the Main switch RCD and MCB
2 1048766 Disconnect all loads
3 1048766 Switch on all switches in the circuit
4 1048766 Disconnect the fusesfinal circuit breakers and close the circuit
5 1048766 Carry out the test as shown in Figure 83
6 1048766 The meter reading value shall be less than 1Ω
57 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
58 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
CONTINUITY TEST
Insulation Resistance Test
i Ensure that there is no leakage current between phase conductors phase and neutral conductors and
phase conductor and earth
ii Test the strength of the cable insulation
iii Test Equipment ndash Insulation Resistance Tester operating voltage is 250VDC or 500VDC
iv Test Method
1 1048766 Switch off main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
59 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
4 1048766 Carry out test as in the Table below
5 1048766 Meter reading value shall be less than 1 Megaohm
60 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
61 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Insulation resitance test
62 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
INSULATION RESISTANCE TEST BETWEEN CONDUCTORS AND OPPOSITE POLARITY
Polarity Testi Ensure that each fuse or single pole control and protection device is connected only in the phase
conductor
ii Intermediate contact of Edison screw lamp holder is connected to the phase conductor
iii Ensure that phase neutral and earth conductors at socket outlets are connected at the correct
terminals
iv Test Equipment ndash Multimeter (Ohm range) or Ohm meter
v Test Method
1 1048766 Switch off Main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in Figure 85
63 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
5 1048766 Test switches and single phase control devices at the phase conductors
6 1048766 Test socket outlet connection sources
7 1048766 Test Edison screw lamp holder connections
8 1048766 Meter reading value shall be less than 1 Ω
64 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Polarity test
65 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Earth Electrode Resistance Testi To test the earth electrode resistance
ii To ascertain the suitability of the location of the electrode
iii To ensure that the electrode is not buried within the resistance area of another electrode
iv Test equipment ndash Earth Resistance Tester
v Test method -
1 1048766 Terminal rsquoErsquo is connected to the electrode to be tested (green conductor)
2 1048766 Terminal lsquoPrsquo is connected to the potential spike (yellow conductor) at a distance of 10
meters from the earth electrode
3 1048766 Terminal lsquoCrsquo is connected to the current spike (red conductor) at a distance of 20 meters
from the earth electrode
Earth Electrode Resistance Measurement Method (Figure 86)
This test must be repeated at least three times to ensure that the reading is not affected by interacting
earthing regions
i Record the first reading (Z1) Example Z1 = 10 Ω
ii Move the voltage spike to a distance of 6 meters from the original position Record the second
reading (Z2 ) Example Z2 = 10 Ω
iii Move the voltage spike to a distance of 6 meters from the original position Record the third
reading (Z3) Example Z3 = 10 Ω
66 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Residual Current Device Testi Ensure that the residual current device (RCD) trips within the set time on the occurrence of current
leakage to earth
ii Test Equipment ndash RCD Tester RCCB Tester
iii Test Method 1
1 1048766 Use the Trip Test Button
2 1048766 Press the trip button found on the RCD to determine if it trips or otherwise This test would
not be able to determine the sensitivity of the RCD nor the time taken for it to trip
iv Test Method 2
i 1048766 Use a RCD Tester
ii This equipment is equipped with a 13A plug which can be connected to a 13A socket outlet
Select the RCD sensitivity to be the same as the sensitivity of the RCD to be tested to
determine if the RCD can trip The time to trip shall not exceed 40 mS
iii 1048766 Test method ndash
a) Position the selection switch in accordance with the sensitivity of the RCD used
Example 100 mA 01 A
b) Position the operations switch to lsquoNo Triprsquo (frac12 Rated mA = 50) connect the 3 pin plug to
the 13A socket outlet
67 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
c) Switch on the 13A socket outlet ndash ensure that the P-N and P-E lights light up
This shows that the polarity is correct (Note if both the lights as above do not light up the test cannot
be continued)
d) Press the test button ndash the reading shows less than 200 mS and simultaneously the lsquotestrsquo light lights
up and the P-N and P-E lights do not light up At that instant the RCD will not trip
e) Move the selection switch to 180o (+ve wave) ndash repeat steps (d) and (e) Move the operations
switch to lsquoTriprsquo (Rated mA = 100)
g) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200mS
h) Move the selection switch to 0o (-ve wave)
i) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
j) The above test is repeated until a near correct reading is obtained
k) Record the test results
l) Change the operations switch to lsquoFast Triprsquo and press the test button ndash RCD will trip within a
time not exceeding 40 millisecond
m) Repeat a number of times at 0o or 180o
On completion of a wiring installation a number of tests on the installation have to be conducted to
ascertain that the wiring circuits and connected appliances are safe for use Prior to carrying out the
tests an inspection has to be done the following tests shall be conducted
i Continuity Test
ii Insulation Resistance Test
iii Polarity Test
iv Earth Electrode Resistance test and
v Residual Current Device Test
821 Continuity Test
There are 3 main types of continuity tests for the final circuits-
i Protection Conductor Continuity Test
ii Final Ring Circuit Conductor Continuity Test
68 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
iii Live and Neutral Conductor Continuity Test
a) Protection Conductor Continuity Test
bull To ascertain that all protection conductors are connected in the correct and effective manner
bull Test equipment ndash Multimeter (Ohm range) or Ohm meter
bull Test Method
1 1048766 Ensure that the main switch RCD and MCB are open circuited (switched off) and all loads are
disconnected
2 1048766 Connected the test leads as in the Figure 81
3 1048766 The meter reading shall be less than 1 Ω
Final Ring Circuit Conductor Continuity Test
bull To ensure that all conductors around the ring circuit have continuity
bull Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
bull Test Method
1 1048766 Disconnect both the supply source live conductors from the MCB the neutral conductor
from the neutral terminals and the earth conductor from the earth terminal in the distribution
fuse box
2 1048766 Connect the test leads as in the Figure 82 (EE)
3 1048766 Repeat the procedure for (L-L) and (N-N)
4 1048766 The meter reading value shall be less than 1 ohm Figure 82 - Final Ring Circuit Conductor
Continuity Test Ohm Meter
Disconnect both the supply source cables from mcbfuse
Take readings at earth conductors of both sources and note resistance readings
Live and Neutral Conductor Continuity Test
1 To ensure that each conductor in the circuit has continuity
2 Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
3 Test Method
1 1048766 Switch off the Main switch RCD and MCB
2 1048766 Disconnect all loads
3 1048766 Switch on all switches in the circuit
4 1048766 Disconnect the fusesfinal circuit breakers and close the circuit
5 1048766 Carry out the test as shown in Figure 83
6 1048766 The meter reading value shall be less than 1 ohm Figure 83 - Live and Neutral
Conductor Continuity Test Ohm Meter
Insulation Resistance Test
69 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
i Ensure that there is no leakage current between phase conductors phase and neutral conductors and
phase conductor and earth
ii Test the strength of the cable insulation
iii Test Equipment ndash Insulation Resistance Tester Operating voltage is 250VDC or 500VDC
iv Test Method
1 1048766 Switch off main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in the Table below
5 1048766 Meter reading value shall be less than 1 Megaohm
Polarity Test
i Ensure that each fuse or single pole control and protection device is connected only in the phase
conductor
ii Intermediate contact of Edison screw lamp holder is connected to the phase conductor
iii Ensure that phase neutral and earth conductors at socket outlets are connected at the correct
terminals
iv Test Equipment ndash Multimeter (Ohm range) or Ohm meter
v Test Method
1 1048766 Switch off Main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in Figure 85
5 1048766 Test switches and single phase control devices at the phase conductors
6 1048766 Test socket outlet connection sources
7 1048766 Test Edison screw lamp holder connections
8 1048766 Meter reading value shall be less than 1 Ω
Earth Electrode Resistance Test
i To test the earth electrode resistance
70 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
ii To ascertain the suitability of the location of the electrode
iii To ensure that the electrode is not buried within the resistance area of another electrode
iv Test equipment ndash Earth Resistance Tester
v Test method -
1 1048766 Terminal rsquoErsquo is connected to the electrode to be tested (green conductor)
2 1048766 Terminal lsquoPrsquo is connected to the potential spike (yellow conductor) at a distance of 10
meters from the earth electrode
3 1048766 Terminal lsquoCrsquo is connected to the current spike (red conductor) at a distance of 20 meters
from the earth electrode E P C Electrode 10 meter 10 meter
Figure 86 ndash Earth Electrode Resistance Measurement Test Equipment
Earth Electrode Resistance Measurement Method (Figure 86)
This test must be repeated at least three times to ensure that the reading is not affected by interacting
earthing regions
i Record the first reading (Z1) Example Z1 = 10 Ω
ii Move the voltage spike to a distance of 6 meters from the original position Record the second
reading (Z2) Example Z2 = 10 Ω
iii Move the voltage spike to a distance of 6 meters from the original position Record the third
reading (Z3)
Example Z3 = 10 Ω
Residual Current Device Test
71 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
i Ensure that the residual current device (RCD) trips within the set time on the occurrence of current
leakage to earth
ii Test Equipment ndash RCD Tester RCCB Tester
iii Test Method 1
1 1048766 Use the Trip Test Button
2 1048766 Press the trip button found on the RCD to determine if it trips or otherwise This test would
not be able to determine the sensitivity of the RCD nor the time taken for it to trip
iv Test Method 2
1048766 Use a RCD Tester
This equipment is equipped with a 13A plug which can be connected to a 13A socket outlet Select the
RCD sensitivity to be the same as the sensitivity of the RCD to be tested to determine if the RCD can
trip The time to trip shall not exceed 40 mS
1048766 Test method ndash
a) Position the selection switch in accordance with the sensitivity of the RCD used
Example 100 mA 01 A
b) Position the operations switch to lsquoNo Triprsquo (frac12 Rated mA = 50) connect the 3 pin plug to
the 13A socket outlet
c) Switch on the 13A socket outlet ndash ensure that the P-N and P-E lights light up This shows that
the polarity is correct (Note if both the lights as above do not light up the test cannot be
continued)
d) Press the test button ndash the reading shows less than 200 millisecond and simultaneously the
lsquotestrsquo light lights up and the P-N and P-E lights do not light up At that instant the RCD will
not trip
e) Move the selection switch to 180o (+ve wave) ndash repeat steps (d) and (e) = 100)
f) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
g) Move the selection switch to 0o (-ve wave)
h) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
i) The above test is repeated until a near correct reading is obtained
j) Record the test results
k) Change the operations switch to lsquoFast Triprsquo and press the test button ndash RCD will trip within a
time not exceeding 40 mS
l) Repeat a number of times at 0o or 180o
72 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 9 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (DC)
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
73 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Start stop button 240Vac 5A 2
9 Filament lamp (Bulb ) 240Vac 40W 3
10 Overload Relay 415V 20A 3
11 Three phase induction motor 5 hp 3
12 Single phase step down transformer 2500VA 1
13 Single core PVC insulated Cable 1mm 2 As required
14 Single core PVC insulated Cable 25mm 2 As required
15 DIN rail 35 mm As required
16 PVC type Cable tray 50 mm x 50 mm As required
17 Cable ties 4 ldquo As required
18 Flexible wires 05 mm As required
19 PVC Connectors 5 A amp 20 A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the schematic
diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a optional exercise
i Simple DOL starter
ii Forward reverse DOL starter
iii Forward Reverse Dahlander motor
iv Three motors operated in sequence by DOL starter operated by manual push
button or time delay relay
74 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
a One loop per-cycle
b Continuous operation in a loop
c optional circuit design to represent the same task
v Only one out of three motors to be operated at a time (quiz)
4 Test the functionality of completed project
LESSON 10 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (AC)
75 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 1
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Lamp point 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
76 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
11 Overload Relay 415V 20A 3
12 Three phase induction
motor
5 hp 3
13 Single core PVC insulated
Cable
1mm 2 As required
14 Single core PVC insulated
Cable
25mm 2 As required
15 DIN rail 35 mm As required
16 PVC type Cable tray 50 mm x 50 mm As required
17 Cable ties 4 ldquo As required
18 Flexible wires 05 mm As required
19 PVC Connectors 5 A amp 20 A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the
schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram optional exercise
4 Simple DOL starter
5 Forward reverse DOL starter
6 Test the functionality of completed project
77 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 1
78 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
cm
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Indicating light 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
11 Overload Relay 415V 20A 3
12 Three phase induction motor 5 hp 3
13 Single phase step down
transformer
2500VA 1
14 Single core PVC insulated
Cable
1mm 2 As required
15 Single core PVC insulated
Cable
25mm 2 As required
16 DIN rail 35 mm As required
17 PVC type Cable tray 50 mm x 50 mm As required
18 Cable ties 4 ldquo As required
19 Flexible wires 05 mm As required
20 PVC Connectors 5 A amp 20 A 240 V As required
21 Single pole MCB 6A 240 V 1
22 Single pole MCB 2A 240 V 1
23 Triple pole MCB 20A 415 V 1
24 Mounting board 30 cm x 40 cm x 3
cm
1
25 Relay cw 11 pin socket 10 A 240 Vac 2
26 Time delay relay 10 A 240 Vac 3
27 Triple pole Contactor 20A 240Vac 3
28 Batten type Lamp holder 240Vac 10 A 3
29 Start stop button 240Vac 10A 2
30 Indicating light (Bulb ) 240Vac 25W 3
31 Overload Relay 415V 20A 1
32 Three phase dahlander type
induction motor
5 hp 1
33 Single phase step down
transformer
24024Vac
2500VA
1
79 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
34 Single core PVC insulated
Cable
1mm 2 As required
35 Single core PVC insulated
Cable
25mm 2 As required
36 DIN rail 35 mm As required
37 PVC type Cable tray 50 mm x 50 mm As required
38 Cable ties 4 ldquo As required
39 Flexible wires 075 mm As required
40 PVC Connectors 5 A amp 20 A 240 V As required
41 Terminal block 20A 240Vac As required
Procedures
5 Identify each component according to specification and quantity required from the schematic
diagram attached
6 Test the functionality of each component by using multi-meter or power supply whichever
applicable
7 Wire component according to circuit diagram
8 Three motors operated in sequence by DOL starter operated by manual push button or time
delay relay
a One loop per-cycle
b Continuous operation in a loop
c optional circuit design to represent the same task
d Only one out of three motors to be operated at a time (quiz)
9 Test the functionality of completed project
80 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
BASIC DESIGN INDUSTRIAL MOTOR CONTROL (SEQUENCE CONTROL)
THREE PHASE INDUCTION MOTOR OPERATED IN SEQUENCE BY DIRECT ON LINE
STARTER
LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
81 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
82 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Lcd lamp indicator 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
11 Overload Relay 415V 20A 3
12 Three phase induction motor 5 hp 3
13 Single phase step down transformer 2500VA 1
14 Single core PVC insulated Cable 1mm 2 As required
15 Single core PVC insulated Cable 25mm 2 As required
16 DIN rail 35 mm As required
17 PVC type Cable tray 50 mm x 50 mm As required
18 Cable ties 4 ldquo As required
19 Flexible wires 1 mm Oslash As required
20 PVC Terminal block 10A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the schematic
diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a optional exercise
i Forward Reverse dahlander motor
4 Test the functionality of completed project
83 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
THREE PHASE DAHLANDER TYPE INDUCTION MOTOR OPERATED FORWARD AND
REVERSE OPERATION BY DIRECT ON LINE STARTER
84 ndash 99EASYTECH ENTERPRISE
LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
Introduction
If a motors windings are connected in the star configuration any two phases will be in series across
the supply and hence the line current will be smaller(by 577) than if the windings were connected in
the delta arrangement
Hence larger-type motors with heavy starting currents are first connected in star and then when the
starting currents fall in delta This of course means that all six of the ends of the windings must be
brought to terminations outside the casing (Fig 833)
EZTECH
EZTECH ELECTRICAL INSTALLATION GUIDE
The automatic version of this starter incorporates a timing relay which automatically changes the
connections from star to delta Figs 834 and 835 show the wiring and schematic diagrams for a star
delta starter
Objectives
1 Identify component and the specification
2 Design forward reverse star delta starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
2 ndash 99EASYTECH ENTERPRISE
REV -C
LEGENDMCCB Moulded Case Circuit BreakerTOR Thermal Over Load RelayFOW-C Mains Forward ContactorREV-C Mains Reverse ContactorDC Delta ContactorSC Star ContactorS-SW Mains Selector Switch
SC
V2
W2
U2
DC
V1
W1
U1
TOR
TOR
FOW-C
30A MCCB
TOR
MAIN CIRCUIT FORWARD REVERSE STAR DELTA
RYBN S
-SW
3 PHASEINDUCTION MOTOR
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Relay 10 A 240V 3
5 Triple pole Contactor
6 cw NO NC auxiliary contact
240Vac 20 A 4
7 Overload Relay 415 V 1
8 LED indicator 240vac 5 A 4
9 Start stop button 240Vac 5A 2
10 DIN rail 35 mm As required
11 Flexible wires 1 mm As required
12 Single core PVC insulated
wire
25 mm As required
13 Terminal block 20 A As required
14 Squirrel cage motor 5kW 1
15 5 pin plug and socket 415V 20A 1
16 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
3 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
a Manual star delta
b Manual Forward reverse star delta starter
c Automatic star delta starter
d Automatic Forward reverse star delta starter
4 Test the functionality of completed project
4 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
Objectives
1 Identify component and the specification
2 Design auto transformer starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
5 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Autotransformer starter is used to start a 3 phase induction motor that has a rating between 10 to 15 hp
6 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Autotransformer set 10Kw 415 V 50 Hz 1
5 Triple pole Contactor 240Vac 4
6 Batten type Lamp holder 240 Vac 105 A 4
7 Start stop button 240Vac 10A 4
8 Filament lamp (Bulb ) 240Vac 40W 4
9 DIN rail 35 mm As required
10 Flexible wires 1 mm As required
7 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
11 Single core PVC insulated
wire
25 mm As required
12 Terminal block 20 A As required
13 Squirrel cage motor 10kW 1
14 5 pin plug and socket 415V 20A 1
15 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a open transient autotransformer starter
b close transient autotransformer starter
c Forward reverse autotransformer starter
4 Test the functionality of completed project
8 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
Objectives
1 Identify component and the specification
2 Design rotor resistance starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
9 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Rotor Resistor set 10kW 1
5 Triple pole Contactor 240Vac 20A 4
6 Indicating light 240vac 5 A 4
7 Start stop push button 240Vac 5A 4
8 DIN rail 35 mm As required
9 Flexible wires 1 mm 2 As required
10 Single core PVC insulated wire 25 mm 2 As required
11 Terminal block 20 A As required
12 Slip Ring motor 10kW 1
13 5 pin round 3 phase socket 415V 20A 1
14 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
10 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
4 Test the functionality of completed project
a Dead circuit test b Life circuit test
5 Measure starting and running Amps
LESSON 16
TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
An installation in general will suffer damage
Damage usually occurs on the electric motor control as follows
1 Damage to the main circuit
2 Damage to the control circuit
The cause of the damage
i Overcurrent overload short circuit
ii Leakage current to ground
iii Equipment malfunction
iv The main control circuit
a Trip of main circuit protection devices fire
b Defect of motor terminal such as short circuit fire loose
v The control circuit is not functioning -
a contactor relay relay time overload relay does not work damaged burned
b Loose cable connection disconnected
Detecting and Repairing Damage
Examples of damage are as follows
i Motor does not work
ii Motor function and overload relay trips
iii Motor function but only partially functional control circuit
Methods of detecting damage
Among the known methods necessary to detect damage are as follows
1 Turn off the electricity at the main switch (main switch) in order to avoid any danger during the
work carried out to detect damage
2 Check all the protective gear that controls the motor control main circuit
11 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
3 Make sure the damage function control circuit
4 Check the control circuit according to the schematic circuit diagram of the motor control
5 Check the operation of the control circuit
Note
Use wiring that has been installed on the SYSTEM OF MOTOR CONTROL BOARD by Forward
Reverse control circuit for Star Delta to test and look for damage
SELF-ASSESSMENT QUESTIONS
1 (a) Explain what is meant by the term lsquoback emfrsquo in a motor
(b) Outline the basic differences between series shunt and compound wound dc motors
2 (a) With the aid of diagrams explain how the speed of series shunt and compound-wound motors
may be controlled
(b) A 440V dc shunt-wound motor has a field resistance of 200R and an armature resistance of 06 R
When its speed is 20 rev d second the current drawn from the supply is 122A Calculate its back
emf at this speed If the speed were decreased to 19 revssecond the field flux remaining unchanged
calculate the new back emf and the new armature current
3 A load of 64 kW at 240 V is supplied from the terminals of a shunt-wound dc generator The field
resistance is 180 A Calculate the armature current
4 (a) Explain with the aid of a diagram how a rotating magnetic field may be
(b) What is meant by lsquosynchronous speedrsquo
Calculate the synchronous obtained speed of a 12 pole motor if the supply frequency is 50Hz
5 (a) Explain the action of a synchronous motor
(b) What methods are available to start a synchronous motor Explain with diagrams
6 (a) Explain the action of a cage induction motor
(b) What is meant by the term lsquosliprsquo
Calculate the percentage slip of a six pole induction motor running at 162 revssecond from a 50 Hz
supply
7 Describe with sketches three different ways of starting a single-phase induction motor
12 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
8 Explain with the aid of a sketch the action of a three-phase DOL starter
What are dashpots used for How are remote start and stop buttons connected
9 A I0 kW 240V 50Hz single-phase cage rotor induction motor is 85efficient and has a PF of 068
lagging Calculate the motor current and the value of capacitor required to raise the PF to 093
lagging
10 Calculate the torque developed by an 18 kW four-pole induction motor run at 35 slip from a
50Hz supply
APPENDIX 1
13 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 11
14 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 111
Attachment Reference
httpswwwtlc-directcoukBook621htm
httpwwwstgovmyindexphpms
15 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
iii The selected cable must be capable of delivering the electrical energy efficiently
iv The cable size allows it to carry the current without heating the cable
v The voltage drop must not exceed 4 of the supply voltage Refer to Table 4D1B in Appendix III
vi The cable insulation must be suitable for the surrounding conditions of the installation such as the
ability to withstand the surrounding temperatures and the ability to provide mechanical protection
vii Each conductor in the installation must be protected from overcurrent by means of overcurrent
protection devices needed to prevent damage to the cable insulation
32 Factors Related to Cable Current Carrying CapacityThe following factors in relation to the current carrying capacity of cables must be taken into
consideration-
i Surface wiring using clips ndash group factor
ii Wiring using conduits ndash space factor 40
iii Wiring using ducts ndash space factor 45
iv Concealed wiring ndash group factor and
v Concealed wiring using ducts ndash surrounding temperature factor
Use of Minimum Cross Sectional Area Rating of Wiring ConductorsThe following are the minimum cross sectional areas of conductors based on their applications-
Use of Protection Conductor Minimum Cross Sectional Area Rating
In Comparison with Phase Conductor Cross Sectional Area
The following table shows the protection conductor minimum cross sectional area in comparison
with the phase conductor cross sectional area
Functions and Colour Identification of Non Flexible Cables
The following table shows the functions and colour identification of non flexible cables
11 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
33 Use of Minimum Cross Sectional Area Rating of Wiring Conductors
The following are the minimum cross sectional areas of conductors based on their applications-
34 Use of Protection Conductor Minimum Cross Sectional Area Rating
In Comparison with Phase Conductor Cross Sectional Area
The following table shows the protection conductor minimum cross sectional area in comparison
with the phase conductor cross sectional area
Use of Minimum Cross Sectional Area Rating of Wiring Conductors
The following are the minimum cross sectional areas of conductors based on their applications-
Use of Protection Conductor Minimum Cross Sectional Area Rating
In Comparison with Phase Conductor Cross Sectional Area
The following table shows the protection conductor minimum cross sectional area in comparison
with the phase conductor cross sectional area
Functions and Colour Identification of Non Flexible CablesThe following table shows the functions and colour identification of non flexible cables
12 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Flexible Cables
i Flexible cables of cross sectional area less than 40 mm2 are used in installations for electrical
accessories such as ceiling roses lamp fixtures or attachments socket plugs for mobile
appliances etc
ii Flexible cables shall not be used for permanent wiring
iii Flexible cables for the permanent use of electrical appliances should not exceed 3 meters in
length
37 Functions and Colour Identification of Flexible Cables
Conductor Insulation and Types of WiringVarious material and insulation layers are used for conductor protection Cable selection in
accordance to insulation layers must be done correctly for the type of the wiring installation as
shown in the table below
Functions and Colour Identification of Non Flexible CablesThe following table shows the functions and colour identification of non flexible cables
3 SELECTION OF WIRING ACCESSORIES
i All wiring accessories to be used have to be of those approved by the Energy Commission and
labeled with labels issued by SIRIM For all wiring using UPVC conduits -
13 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
a) Switches socket outlets 3 pin plugs ceiling roses connectors sockets ndash construction material shall
be of polycarbonate type
iii For all wiring using metal conduits - Switches socket outlets and connectors ndash construction
material shall be of metal clad type and All accessories shall be effectively earthed
iv Switch fuse used in single phase installations shall have the fuse permanently connected and not
move with the fuse
v Fuse switch used in 3 phase domestic installations also has fuse and switch The fuse connector is
installed together to allow the fuse to move simultaneously with the switch
vi Lamp
a) Fluorescent lamps using magnetic ballasts (watt loss not exceeding 6 watts) shall be
equipped with dry paper type capacitor
b) Fluorescent lamps using electronic ballasts or high frequency electronic ballasts do not
need capacitors
c) Outdoor domestic lamp installations shall use weather proof and water proof lamps
d) Submerged light installations (example in swimming pools fountains etc) shall have water
proof lamps with a voltage not exceeding 12 Volt AC
vii Electric water heaters is divided into 2 types namely
1 instantaneous water heaters and
2 stored water heaters (storage tank type)
a) Instantaneous water heaters shall be equipped with a 2 pole control switch and its own
residual current device
b) Storage water heaters (storage tank type) shall be installed with an
Water heaters exceeding 3kW shall be permanently connected to a 20A30A rated circuit
breakerfuse with an isolator switch and residual current device
viii Electric cookers exceeding 3kW shall have its own circuit connected permanently to a 30A rated
circuit breaker or fuse with an isolator switch and cooker control unit incorporated with a 13A socket
outlet Two or more cooker appliances may be installed in the same room within a distance of 2
meters
ix Electric motors (fence gate air conditioners fountains swimming pools fish ponds water
pumps) exceeding 373W but not exceeding 2238W shall be connected permanently to a 20A30A
rated circuit breakerfuse together with an isolator motor starter and 15A socket outlet
14 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
The motor starter shall be of Direct-On-Line type with the appliance together with the contactor
overload relay and on-off control The circuit breakerfuse which controls the motor circuit shall be
capable of withstanding the starting current of the motor
x Electric bells ndash the circuit shall have a push button switch and a ACDC transformer
xi Ceiling fans shall conform to clause 21101 of the MS 12192002 standard with regards to test on
the suspension system of ceiling fans
EARTHING OF ELECTRICAL INSTALLATIONS51 Earthing
Earthing is a connection system between the metallic parts of an electrical wiring system and the
general mass of the earth This will provide an easy path with a low impedence or resistance to earth to
enable the protection system to operate effectively It will thus ensure safety to human
beingsconsumers from the dangers of electric shocks if earth leakage currents are present In general
an electrical installation is earthed because of -
i Safety reasons
ii Protection system requirements
iii Need to limit over voltages
iv Need to provide a path for electrical discharge
v Legal requirements
52 Classification of Earthing
Generally earthing can be divided into 2 parts namely -
i System Earthing
a To isolate the system under fault conditions
b To limit the potential difference between conductors which are not insulated in an area
c To limit the occurrence of over voltages under various conditions
ii Equipment Earthing
Equipment earthing is undertaken to protect human beingsconsumers If a live source comes into
contact with the equipment body electrical energy will flow to the earth without flowing through the
human being consumerrsquos body This is because of the fact that the human body has a greater
resistance compared with the resistance to earth
53 Types and Functions of Earthing Accessories
Earthing accessories are as follows -
i Earthing Electrode
Copper jacketed steel core rods are used as electrodes for domestic wiring
ii Equipotential Bonding
15 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
This is the conductor which is connected between the consumer earthing point and the exposed
metallic part The minimum cable size for this purpose is 10 mm2
iii Protection Conductor
This is the conductor which connects the consumer earthing point with other parts of the installation
which needs earthing Its size is as follows-
a) Same size as the phase cable up to a size of 16mm2
b) 16 mm2 if the phase cable size is between 16 mm2 and 35 mm2
c) Half the size of the phase cable if the size of the phase cable exceeds 35 mm2
54 Earthing Arrangements Using a TT System
i The first alphabet indicates the earthing arrangements from the supply side
ii The second alphabet indicates the earthing arrangement in the consumerrsquos installation
T ndash first Indicates that the supply system has its own earthing arrangements
T ndash second Indicates that all metallic frames of the electrical appliances etc are connected directly to
earth
Parts that are Required to be Earthed
i All metallic structures in the wiring system (non current carrying) such as metallic covers conduits
ducts the armour of catenary wires etc
ii A secondary winding point in a transformer and
iii Frame of metal roof truss
56 Parts that are not Required to be Earthed
i Short isolated metallic parts for mechanical protection of cables which have non metallic sheaths
other than conduits which are connected at entry points between the building and conduits which
protect discharge lamp cables
ii Cable clips for installing cables
iii Metallic covers for lamps
16 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
iv Small metallic parts such as screws and name plates which are isolated by means of insulation
v Metallic lamp parts for filament lamps in water proof floors
57 Termination to Earth
The termination to earth is done as shown in Figure 72
Earth Electrode Resistance
The maximum permitted earth electrode resistance for different types of installations is as shown in
the Table below
Earth electrode for installations protected by RCDs of sensitivity 100mA 10 Ω
Lightning arrestor earth electrode 10 Ω
Legal Requirements
i Sub regulation 12(1) and 12(2) of the Electricity Regulations 1994 state that any electrical wiring in
an installation shall be under the immediate supervision of a Wireman with Single Phase Restriction or
Three Phase Restriction Upon completion the Wireman shall certify a Supervision and Completion
Certificate
ii Sub regulation 13(1) and 13 (2) of the Electricity Regulations 1994 state that the installation shall
be tested by a Wireman with Single Phase Restriction or a Wireman with Three Phase Restriction
authorized to test any installation and who shall certify a Test Certificate for the installation
iii Sub regulation 14(1) of the Electricity Regulations 1994 states that the Supervision and
Completion Certificate and the Test Certificate as in regulations 12 and 13 shall be in Forms G and H
respectively as prescribed in the First Schedule
17 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
4 SAFETY REQUIREMENTS FOR ELECTRICAL WIRING WORKS IN RESIDENTIAL BUILDINGS
61 Safety Requirements
Safety requirements for electrical wiring works have to be followed to eliminate any accidents which
can result in physical damage or loss of life or property Failure to meet the safety regulations may
result in workers consumers or the public being inflicted with electrical shocks
In addition to this safety steps will also encourage workers or electricity consumers who are
disciplined and who always give importance to safety
62 Safety Steps
Safety requirements have to be followed whenever electrical works are undertaken in a residential
building
i Personal Safety
a Use suitable personal protection equipment as needed such as safety shoes gloves safety helmet
etc when at the work place
b Use safety clothing suitable for the work to be undertaken
c Do not wear jewellery or decorative items such as rings watches chains etc while carrying out
electrical works
ii Safety at the Work Place
a Acquire knowledge about the dangers of electrical works that is to be undertaken and how to deal
with those dangers
b Always adhere to the safety regulations which have been set for the work place
c Ensure that the electricity supply is switched off before carrying out the works
d Acquire the needed knowledge and practice a cautious and calm attitude while working ensure
cleanliness in and around fellow workers
e While working at elevated places the worker should always use suitable equipment such as wooden
or aluminium ladders iron scaffoldings or platforms safety belts or other equipment needed to ensure
that the work can be undertaken safely
f Use electrical equipment which is operational and safe to be used and ensure that the supply for it is
being supplied through a residual current device (RCD) with a sensitivity of 30 mA
g Ensure that exposed temporary supply electrical cables have mechanical protection
h If inflammable or corrosive material is present necessary safety steps have to be undertaken as
required by the relevant safety regulations
63 Dangers of Electrical Shocks
i Electrical Shock
Electrical shocks can occur due to direct or indirect contact
a Direct Contact
18 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Direct contact occurs when the worker or consumer receives an electrical shock on touching directly a
live conductor or cable
b Indirect Contact
Here the electric shock occurs due to contact with a part which is connected to the electrical
installation and not to a direct contact with a live cable or conductor possibly due to damages in the
appliance or insulation resulting in leakages of current
Why Electric Shocks Occura Unsafe Work Method or Action Undertaking Electrical Work Without Disconnecting the
Supply
Maintenance or circuit testing work done without disconnecting the supply will have a high possibility
of electrical shocks occurring
bull Not Following Safe Work Procedures
To eliminate the occurrence of electrical shocks each worker has to always follow safe work
procedures which are set by regulations and standards
b Defects in the Electrical System
i Leakage Current
Leakage currents or earth leakage currents can result in the metallic frames becoming live and
energised This can give rise to the danger of electrical shock to the worker consumer or the public if
they hold or come into contact with the metallic frame
ii Exposed Conductor or Disconnected Cable
Exposed conductors or cables which are broken and are alive (energised) can result in electrical shock
when touched The supply source must be immediately isolated or switched off and a report must be
made to the responsible entity
64 First Aid and Basic Pulmonary Resuscitation
i First Aid
First aid is the initial assistance given to a person who has met with an accident is sick or is injured to
prevent the condition of the victim from becoming more serious while awaiting the arrival of the
paramedics (ambulance) or before being brought to the hospital
i Pulmonary Resuscitation
Pulmonary resuscitation has to be undertaken to assist the victim who has breathing difficulties as a
result of being drowned receiving an electrical shock etc Pulmonary resuscitation has to be carried
out in accordance to the correct method as stated in the first aid manuals issued by accredited first aid
bodies
ii First Aid Box
19 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
A first aid box has to be provided by the building owner construction site supervisor or brought
personally by the worker under the supervision of the responsible person
65 Training Programme
The management shall conduct periodic training programmes for the workers with regards to work
safety on aspects including the following -
i Dangers of electrical work being undertaken and how to control those dangers
ii The safety regulations set for the work place and
iii First aid procedures
66 Fire Prevention
Fire Extinguisher A suitable functioning fire extinguisher to control fires has to be made available at
the work place at all times
67 Competent Person
The Electricity Regulations 1994 require that all electrical work has to be undertaken by or under the
direct supervision of a competent person registered with the Energy Commission Besides that the
electrical contractor undertaking the electrical work has also to be registered with the Energy
Commission The installation owner thus has to ensure that the appointed electrical contractor is
registered with the Energy Commission and that the registration is still valid
INSTALLATION CIRCUITS AND SYSTEMS1 Block diagrams
These show using squares rectangles etc the sequence of a system without too much technical detail
eg Figures 1517 and 1526
2 Layout diagrams
These are very similar to block diagrams but they indicate more technical detail and tend to show
items in their correct geographical location (eg Figures 1518 and 1519)
3 Circuitschematic
These show how a circuit functions and takes no account of exact locations of terminals or equipment
(eg Figures 1528 1529 1532 1534 etc)
4 Wiring diagram
These indicate how a circuit or system is physically wired (eg Figures 152 154 156 etc)
Most induction motors are started directly on line but when very large motors are started that way
they cause a disturbance of voltage on the supply lines due to large starting current surges To limit the
starting current surge large induction motors are started at reduced voltage and then have full supply
voltage reconnected when they run up to near rotated speed Two methods are used for reduction of
starting voltage are star delta starting and auto transformer stating
20 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Working Principal of Star-Delta Starter
This is the reduced voltage starting method Voltage reduction during star-delta starting is achieved by
physically reconfiguring the motor windings as illustrated in the figure below During starting the
motor windings are connected in star configuration and this reduces the voltage across each winding 3
This also reduces the torque by a factor of three After a period of time the winding are reconfigured as
delta and the motor runs normally
StarDelta starters are probably the most common reduced voltage starters They are used in
an attempt to reduce the start current applied to the motor during start as a means of reducing the
disturbances and interference on the electrical supply
Traditionally in many supply regions there has been a requirement to fit a reduced voltage
starter on all motors greater than 5HP (4KW) The StarDelta (or WyeDelta) starter is one of the
lowest cost electromechanical reduced voltage starters that can be applied
The StarDelta starter is manufactured from three contactors a timer and a thermal overload
The contactors are smaller than the single contactor used in a Direct on Line starter as they are
controlling winding currents only The currents through the winding are 1root 3 (58) of the
current in the line
There are two contactors that are close during run often referred to as the main contractor and
the delta contactor These are AC3 rated at 58 of the current rating of the motor The third
contactor is the star contactor and that only carries star current while the motor is connected in star
The current in star is one third of the current in delta so this contactor can be AC3 rated at one
third (33) of the motor rating
Star-delta Starter Consists following units
1) Contactors (Main star and delta contactors) 3 Norsquos (For Open State Starter) or 4 Norsquos (Close
Transient Starter)
2) Time relay (pull-in delayed) 1 No
3) Three-pole thermal over current release 1No
4) Fuse elements or automatic cut-outs for the main circuit 3 Nos
5) Fuse element or automatic cut-out for the control circuit 1No
Power Circuit of Star Delta Starter
1 The main circuit breaker serves as the main power supply switch that supplies electricity to the
power circuit
2 The main contactor connects the reference source voltage R Y B to the primary terminal of the
motor U1 V1 W1
21 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
3 In operation the Main Contactor (KM3) and the Star Contactor (KM1) are closed initially and
then after a period of time the star contactor is opened and then the delta contactor (KM2) is
closed The control of the contactors is by the timer (K1T) built into the starter The Star and Delta
are electrically interlocked and preferably mechanically interlocked as well In effect there are
four states
4 The star contactor serves to initially short the secondary terminal of the motor U2 V2 W2 for the
start sequence during the initial run of the motor from standstill This provides one third of DOL
current to the motor thus reducing the high inrush current inherent with large capacity motors at
startup
5 Controlling the interchanging star connection and delta connection of an AC induction motor is
achieved by means of a star delta or wye delta control circuit The control circuit consists of push
button switches auxiliary contacts and a timer
Control Circuit of Star-Delta Starter (Open Transition)
1 The ON push button starts the circuit by initially energizing Star Contactor Coil (KM1) of star
circuit and Timer Coil (KT) circuit
2 When Star Contactor Coil (KM1) energized Star Main and Auxiliary contactor change its
position from NO to NC
3 When Star Auxiliary Contactor (1)( which is placed on Main Contactor coil circuit )became
NO to NC itrsquos complete The Circuit of Main contactor Coil (KM3) so Main Contactor Coil
energized and Main Contactorrsquos Main and Auxiliary Contactor Change its Position from NO
To NC This sequence happens in a friction of time
4 After pushing the ON push button switch the auxiliary contact of the main contactor coil (2)
which is connected in parallel across the ON push button will become NO to NC thereby
providing a latch to hold the main contactor coil activated which eventually maintains the
control circuit active even after releasing the ON push button switch
5 When Star Main Contactor (KM1) close its connect Motor connects on STAR and itrsquos
connected in STAR until Time Delay Auxiliary contact KT (3) become NC to NO
6 Once the time delay is reached its specified Time the timerrsquos auxiliary contacts (KT)(3) in
Star Coil circuit will change its position from NC to NO and at the Same Time Auxiliary
contactor (KT) in Delta Coil Circuit(4) change its Position from NO To NC so Delta coil
energized and Delta Main Contactor becomes NO To NC Now Motor terminal connection
change from star to delta connection
7 A normally close auxiliary contact from both star and delta contactors (5amp6)are also placed
opposite of both star and delta contactor coils these interlock contacts serves as safety
switches to prevent simultaneous activation of both star and delta contactor coils so that one
22 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
cannot be activated without the other deactivated first Thus the delta contactor coil cannot be
active when the star contactor coil is active and similarly the star contactor coil cannot also
be active while the delta contactor coil is active
8 The control circuit above also provides two interrupting contacts to shutdown the motor
The OFF push button switch break the control circuit and the motor when necessary The
thermal overload contact is a protective device which automatically opens the STOP Control
circuit in case when motor overload current is detected by the thermal overload relay this is to
prevent burning of the motor in case of excessive load beyond the rated capacity of the motor
is detected by the thermal overload relay
9 At some point during starting it is necessary to change from a star connected winding to a
delta connected winding Power and control circuits can be arranged to this in one of two
ways ndash open transition or closed transition
What is Open or Closed Transition Starting
(1) Open Transition Starters
Discuss mention above is called open transition switching because there is an open state between
the star state and the delta state
In open transition the power is disconnected from the motor while the winding are reconfigured via
external switching
When a motor is driven by the supply either at full speed or at part speed there is a rotating
magnetic field in the stator This field is rotating at line frequency The flux from the stator field
induces a current in the rotor and this in turn results in a rotor magnetic field
When the motor is disconnected from the supply (open transition) there is a spinning rotor within
the stator and the rotor has a magnetic field Due to the low impedance of the rotor circuit the time
constant is quite long and the action of the spinning rotor field within the stator is that of a
generator which generates voltage at a frequency determined by the speed of the rotor When the
motor is reconnected to the supply it is reclosing onto an unsynchronized generator and this result
in a very high current and torque transient The magnitude of the transient is dependent on the
phase relationship between the generated voltage and the line voltage at the point of closure can
be much higher than DOL current and torque and can result in electrical and mechanical damage
Open transition starting is the easiest to implement in terms or cost and circuitry and if the timing
of the changeover is good this method can work well In practice though it is difficult to set the
necessary timing to operate correctly and disconnectionreconnection of the supply can cause
significant voltagecurrent transients
In Open transition there are Four states
23 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 OFF State All Contactors are open
2 Star State The Main [KM3] and the Star [KM1] contactors are closed and the delta [KM2]
contactor is open The motor is connected in star and will produce one third of DOL torque at one
third of DOL current
3 Open State This type of operation is called open transition switching because there is an
open state between the star state and the delta state The Main contractor is closed and the Delta
and Star contactors are open There is voltage on one end of the motor windings but the other end
is open so no current can flow The motor has a spinning rotor and behaves like a generator
4 Delta State The Main and the Delta contactors are closed The Star contactor is open The
motor is connected to full line voltage and full power and torque are available
(2) Closed Transition StarDelta Starter
There is a technique to reduce the magnitude of the switching transients This requires the use of a
fourth contactor and a set of three resistors The resistors must be sized such that considerable
current is able to flow in the motor windings while they are in circuit
The auxiliary contactor and resistors are connected across the delta contactor In operation just
before the star contactor opens the auxiliary contactor closes resulting in current flow via the
resistors into the star connection Once the star contactor opens current is able to flow round
through the motor windings to the supply via the resistors These resistors are then shorted by the
delta contactor If the resistance of the resistors is too high they will not swamp the voltage
generated by the motor and will serve no purpose
In closed transition the power is maintained to the motor at all time This is achieved by
introducing resistors to take up the current flow during the winding changeover A fourth
contractor is required to place the resistor in circuit before opening the star contactor and then
removing the resistors once the delta contactor is closed These resistors need to be sized to carry
the motor current In addition to requiring more switching devices the control circuit is more
complicated due to the need to carry out resistor switching
In Close transition there are Four states
1 OFF State All Contactors are open
2 Star State The Main [KM3] and the Star [KM1] contactors are closed and the delta [KM2]
contactor is open The motor is connected in star and will produce one third of DOL torque at one
third of DOL current
Star Transition State The motor is connected in star and the resistors are connected across the
delta contactor via the aux [KM4] contactor
24 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Closed Transition State The Main [KM3] contactor is closed and the Delta [KM2] and Star
[KM1] contactors are open Current flows through the motor windings and the transition resistors
via KM4
Delta State The Main and the Delta contactors are closed The transition resistors are shorted out
The Star contactor is open The motor is connected to full line voltage and full power and torque
are available
Effect of Transient in Starter (Open Transient starter)
It is Important the pause between star contactor switch off and Delta contactor switch is on correct
This is because Star contactor must be reliably disconnected before Delta contactor is activated It
is also important that the switch over pause is not too long
For 415v Star Connection voltage is effectively reduced to 58 or 240v The equivalent of 33
that is obtained with Direct Online (DOL) starting
If Star connection has sufficient torque to run up to 75 or 80 of full load speed then the motor
can be connected in Delta mode
When connected to Delta configuration the phase voltage increases by a ratio of V3 or 173 The
phase currents increase by the same ratio The line current increases three times its value in star
connection
During transition period of switchover the motor must be free running with little deceleration
While this is happening ldquoCoastingrdquo it may generate a voltage of its own and on connection to the
supply this voltage can randomly add to or subtract from the applied line voltage This is known as
transient current Only lasting a few milliseconds it causes voltage surges and spikes Known as
a changeover transient
Size of each part of Star-Delta starter
(1) Size of Over Load Relay
For a star-delta starter there is a possibility to place the overload protection in two positions in the
line or in the windings
Overload Relay in Line
In the line is the same as just putting the overload before the motor as with a DOL starter
The rating of Overload (In Line) = FLC of Motor
Disadvantage If the overload is set to FLC then it is not protecting the motor while it is in delta
(setting is x1732 too high)
Overload Relay in Winding
25 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
In the windings means that the overload is placed after the point where the wiring to the contactors
are split into main and delta The overload then always measures the current inside the windings
The setting of Overload Relay (In Winding) =058 X FLC (line current)
Disadvantage We must use separate short circuit and overload protections
(2) Size of Main and Delta Contractor
1 There are two contactors that are close during run often referred to as the main contractor and
the delta contactor These are AC3 rated at 58 of the current rating of the motor
Size of Main Contactor= IFL x 058
(3) Size of Star Contractor
The third contactor is the star contactor and that only carries star current while the motor is
connected in star The current in star is 1 radic3= (58) of the current in delta so this contactor can
be AC3 rated at one third (33) of the motor rating
Size of Star Contactor= IFL x 033
Motor Starting Characteristics of Star-Delta Starter
Available starting current 33 Full Load Current
Peak starting current 13 to 26 Full Load Current
Peak starting torque 33 Full Load Torque
Advantages of Star-Delta starter
The operation of the star-delta method is simple and rugged
It is relatively cheap compared to other reduced voltage methods
Good TorqueCurrent Performance
It draws 2 times starting current of the full load ampere of the motor connected
Disadvantages of Star-Delta starter
Low Starting Torque (Torque = (Square of Voltage) is also reduce)
Break In Supply ndash Possible Transients
Six Terminal Motor Required (Delta Connected)
It requires 2 set of cables from starter to motor
It provides only 33 starting torque and if the load connected to the subject motor requires higher
starting torque at the time of starting than very heavy transients and stresses are produced while
changing from star to delta connections and because of these transients and stresses many
electrical and mechanical break-down occurs
26 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
In this method of starting initially motor is connected in star and then after change over the motor
is connected in delta The delta of motor is formed in starter and not on motor terminals
High transmission and current peaks When starting up pumps and fans for example the load
torque is low at the beginning of the start and increases with the square of the speed When
reaching approx 80-85 of the motor rated speed the load torque is equal to the motor torque and
the acceleration ceases To reach the rated speed a switch over to delta position is necessary and
this will very often result in high transmission and current peaks In some cases the current peak
can reach a value that is even bigger than for a DOL start
Applications with a load torque higher than 50 of the motor rated torque will not be able to start
using the start-delta starter
Low Starting Torque The star-delta (wye-delta) starting method controls whether the lead
connections from the motor are configured in a star or delta electrical connection The initial
connection should be in the star pattern that results in a reduction of the line voltage by a factor of
1radic3 (577) to the motor and the current is reduced to 13 of the current at full voltage but the
starting torque is also reduced 13 to 15 of the DOL starting torque
The transition from star to delta transition usually occurs once nominal speed is reached but is
sometimes performed as low as 50 of nominal speed which make transient Sparks
Features of star-delta starting
1 For low- to high-power three-phase motors
2 Reduced starting current
3 Six connection cables
4 Reduced starting torque
5 Current peak on changeover from star to delta
6 Mechanical load on changeover from star to delta
Application of Star-Delta Starter
The star-delta method is usually only applied to low to medium voltage and light starting
Torque motors
The received starting current is about 30 of the starting current during direct on line start and the
starting torque is reduced to about 25 of the torque available at a DOL start This starting
method only works when the application is light loaded during the start If the motor is too heavily
27 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
loaded there will not be enough torque to accelerate the motor up to speed before switching over
to the delta position
LESSON 1 WIRING SYSTEM OF SINGLE PHASE DISTRIBUTION BOARD
Introduction
28 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
29 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
30 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
31 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 2 WIRING SYSTEM OF SINGLE PHASE LIGHTING CIRCUIT Introduction
Objectives
1 Identify component and the specification
2 Wire component according to the schematic diagram
3 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Wiring bay Perforated metal 180 cm x 180 cm 1
2 Cut out fuse 63 A 240 V 1
3 Neutral link 1
4 Single pole one way switch cw
switch box
5A 240Vac 4
5 single pole two way switch cw
switch box
5A 240Vac 2
6 RCCB In = 40 A Tripping current
100mA240 Vac 50 Hz
1
7 Main switch 32 A 240V 1
8 kWatthour meter 40 A 240 Vac 1
9 Single pole MCB 6A 240 Vac 1
10 Self tapping Wood screw As required
11 DIN rail 35 mm width As required
32 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
12 PVC trunking 50 mm x 50 mm As required
13 Terminal blocks 5 A As required
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
1 One way switch to control one lamp
2 One way switch to control two lamps
3 Two of two way switch to control one lamp
4 Two of single pole two way switch and one of an intermediate switch to control one
lamp
5 One unit of ceiling fan and fan regulator to be controlled by one way switch
4 Test the functionality of completed project
LESSON 3ndash WIRING SYSTEM OF SINGLE PHASE POWER CIRCUIT Introduction
33 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
34 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify types of component and its specification
2 Wire component according to the schematic diagram given
3 Test the functionality of the circuit dead circuit test life circuit test
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board Perforated Metal 1
2 kWh meter 240 V 40 A 1
3 Socket outlet 13A 240Vac 4
4 RCCB 40A Trip Amps
30mA240 Vac
1
5 3 pin socket 240Vac 13A 4
6 Single pole MCB 20A 240 V 2
7 DOL starter 1 kW 240Vac 2
8 1 phase induction motor 2Hp 240 Vac 1
9 Cooker control unit 4kW 240Vac 1
10 Water heater point 4kW 240 Vac 1
11 DIN rail 35 mm As required
12 PVC casing 20mm As required
13 Flexible wires 05 mm As required
14 Terminal block 10 A As required
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Wire two unit of 13 A socket outlet in radial circuit
3 Wire four units of 13 A socket outlet in ring circuit
4 Wire one unit DOL starter for air-conditioner point
5 Wire one unit of cooker control unit point
6 Wire one unit of water heater point
7 Test the functionality of each component by using mmeter or power supply whichever
applicable
8 Wire component according to circuit diagram
9 Test the functionality of completed project dead circuit test life circuit test
Note
35 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Ensure that the correct rating of protection device and size of wire used
LESSON 4ndash CONDUIT BENDING AND TRUNKING FABRICATION TECHNIQUE
Common fitting used in an industrial wiring
Cutting and threading the condute
36 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
37 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
38 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify conduit fitting and the specification
2 Measure and Cut steel conduit according to specified dimension
3 Bend and fabricate conduit at 45 90 according to layout diagram
4 Wire component according to the schematic diagram
5 Test the functionality of the circuit
39 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Conduit Bender Oslash 19 mm ( frac34 ldquo) 1
2 Measuring Tape 3 metre 1
3 Hacksaw frame and blade 30cm 1
4 Conduit cutter 1
5 Pipe Vise 1
6 Pipe Wrench 1
7 Ratchet Dies 20 mm 1
8 Metal trunking 50 mm x 50 mm 1
9 GI conduit 20mm 1
10 End box 20 mm 1
11 Flexible wires 05 mm As required
12 Connectors 5 A As required
13 Single core PVC ins Cable 25 mm 2 As required
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Wire two unit of 13 A socket outlet in radial circuit
3 Wire four unit of 13 A socket outlet in ring circuit
4 Wire one unit DOL starter for air-conditioner point
5 Wire one unit of cooker control unit point
6 Wire one unit of water heater point
7 Test the functionality of each component by using multimeter or power supply whichever
applicable
8 Wire component according to circuit diagram
9 Test the functionality of completed project
Note
Ensure that the rating of protection device and size of wire
K prior to 31 March
2004 (BS 7671)
(formerly)
bare conductor
sleeved at terminations (formerly)
40 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 5 ndashWIRING SYSTEM OF 1 Oslash LIGHTING AND POWER CIRCUIT
POWER CIRCUITSa Radial circuits
Radial circuits are arranged in the same way as item 1 above in lighting layouts in that each socket
outlet is supplied via the previous one
Points to note
1 The number of socket outlets complying with BS 1363 is unlimited for a floor area of up to 50m 2 if
the circuit protection is a 30 A or 32 A cartridge fuse or circuit breaker the cable being 4 mm PVC
copper or 25 mm2 mineral insulated (mi)
2 The number of socket outlets is unlimited for a floor area up to 20 m 2 with any type of circuit
protection of 20 A using 25 mm2 PVC copper cable or 15 mm2 mi
3 The total number of fused spurs is unlimited
b ring final circuits
These circuits are the same as radial circuits except that the final socket outlet is wired back to the
supply position In effect any outlet is supplied from two directions (Fig 152)
Points to note
1 Every twin-socket outlet counts as two single-socket outlets
2 The number of non-fused spurs must not exceed the total number of points on the ring Fig 158
shows seven points on the ring and five spurs
3 The fuse rating of a fused spur box must not exceed 13 A and the current rating of all points supplied
by the fused spur must not exceed 13 A
4 Non-fused spurs must supply no more than one single or one double socket on the ring Fig 158
shows seven points on the ring and five spurs rating of all points supplied by the fused spur must not
exceed 13 A or one stationary appliance
CapacityMain conductor size
copper (mm2)
Earth conductor
size (mm2)
Circuit breaker
capacity (A)
Up to 600 W 15 15 6
600ndash1200 W 1525 15 10
1200ndash1800 W 254 25 16
41 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Ring circuit
(floor area 100 m2)25 15 3032
A2 radial circuit
(floor area 75 m2)40 25 3032
A3 radial circuit
(floor area 50 m2)25 15 20
Air conditioner (15 tonne) 60 60 3032
Cooker 60 60 3032
Water heater 40 40 20
Objectives
1 Identify component and the specification
2 Wire component according to the schematic diagram
3 Test the functionality of the circuit
42 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board Perforated 1
2 Cut out fuse and neutral link 60A 240V 1each
3 kWh meter 240V 40A 1
4 Switched Socket outlet 13A 240Vac 4
5 Single pole two way switch cw switch
box
5A 240Vac 2
6 RCCB ELCB 63 A Tripping current 100mA
415 Vac
1
7 3 pin plug 240Vac 13A 4
8 Single pole MCB 20 A 2
9 Single pole MCB 6A 1
10 Single pole MCB 20A 2
11 DOL starter 240Vac 2
12 1 phase induction motor 2hp 240 Vac 1
13 Self tapping Wood screw As required
14 DIN rail Stainless steel allum35 mm As required
15 PVC pipe 20mm dia As required
16 End box 20 mm dia 4
17 Flexible wires 05 mm 2 As required
18 Connectors 5 A As required
Procedures
43 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
4 Test the functionality of completed project
LESSON 6 ndash WIRING SYSTEM OF 3 Oslash DISTRIBUTION BOARD
Introduction
44 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
45 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
46 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
47 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
48 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify each component and the specification
2 Wire component according to the schematic diagram given
3 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting Board 450 x 600 mm Perforated metal 1
2 5 pin round socket and plug 415V ac 32A 1
3 Cut out fuse 60 A 3
4 Neutral link 1
5 kWatt hour meter 415V 60A 1
6 ELCB RCCB 3P+N In=63A415 Vac I trip= 300mA 1
7 ELCB RCCB 3P+N In=63A415 Vac I trip= 30mA 1
8 Single pole MCB 6A 240 V 3
9 Single pole MCB 20A 240 V 3
10 DOL starter 20 A 240Vac 2
11 Socket outlet 15 A 240 Vac 1
12 Switched Socket outlet 13 A 240 Vac 3
13 Led indicating light 5A 240 Vac 3
14 Single pole 4 gang 1 way switch 5A 240 Vac 2
15 Single pole 2 way switch 5A 240 Vac 2
16 1 phase induction motor 1 kW 240Vac 1
17 Metal trunking 30 mm x30 mm As required
18 Self tapping Wood screw 4 mm x 20 mm As required
19 DIN rail 25 mm x 1mm
20 GI steel rigid conduit 20mm As required
21 Flexible conduit 20mm As required
22 End box 20 mm 4
23 Flexible wires 05 mm 2 As required
24 Single core PVC insulated wire 15 mm 2 As required
25 Single core PVC insulated wires 25 mm 2 As required
26 Terminal block 10 A As required
Procedures
49 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify each components and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
4 Test the functionality of completed project
1 dead circuit test
2 life circuit
Note Proper earthing should be made
50 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 7 ndash WIRING SYSTEM OF THREE PHASE LIGHTING AND POWER CIRCUIT
51 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
52 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify component and the specification
2 Wire component according to the schematic diagram
3 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting bay Board Perforated metal 180 cm x 180 cm 1
2 k Watt hour meter 415V 60A 1
3 MCCB 415V 60A
4 ELCB RCCB In=60A415 Vac I trip=30mA 1
5 5 pin round Socket and
plug
415Vac 32A 4
6 Single pole MCB 6A 1
7 Triple pole MCB 20A 2
8 Triple pole Main switch 60A 1
9 DOL starter 240Vac 2
10 3 phase induction motor 2hp 415 Vac 1
11 1 phase induction motor 1
12 Metal trunking 30 mm x30 mm As required
13 Self tapping Wood screw 4 mm x 20 mm As required
14 DIN rail 25 mm x 1mm
15 GI steel rigid conduit 20mm As required
16 Flexible conduit 20mm As required
17 End box 20 mm 4
18 Flexible wires 05 mm As required
19 Connectors 10 A As required
Procedures
1 Identify each components and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
4 Test the functionality of completed project
1 dead circuit 2 life circuit test
5 Record the current drawn by the load as connected in star and delta
Note Proper earthing should be made
53 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 8 INSPECTION AND TESTING OF ELECTRICAL INSTALLATION
On completion of a wiring installation a number of tests on the installation have to be conducted to
ascertain that the wiring circuits and connected appliances are safe for use Prior to carrying out the
tests an inspection has to be done The results of the inspectionsupervision and test have to be
presented in Form G (as in Appendix IV) and Form H (as in Appendix V)
To have the test certification as in Form H the following tests shall be conducted
i Continuity Test
ii Insulation Resistance Test
iii Polarity Test
iv Earth Electrode Resistance test and
v Residual Current Device Test
1 Continuity Test
There are 3 main types of continuity tests for the final circuits-
i Protection Conductor Continuity Test
ii Final Ring Circuit Conductor Continuity Test
iii Live and Neutral Conductor Continuity Test
a) Protection Conductor Continuity Test
bull To ascertain that all protection conductors are connected in the correct and effective manner
bull Test equipment ndash Multimeter (Ohm range) or Ohm meter
54 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
bull Test Method
1 1048766 Ensure that the main switch RCD and MCB are open circuited (switched off) and all loads
are disconnected
2 1048766 Connected the test leads as in the Figure 81 The meter reading shall be less than 1 Ω
55 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Final Ring Circuit Conductor Continuity Test
bull To ensure that all conductors around the ring circuit have continuity
bull Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
bull Test Method
1 1048766 Disconnect both the supply source live conductors from the MCB the neutral conductor
from the neutral terminals and the earth conductor from the earth terminal in the distribution
fuse box
2 1048766 Connect the test leads as in the Figure 82 (EE)
3 1048766 Repeat the procedure for (L-L) and (N-N)
4 1048766 The meter reading value shall be less than 1 ohm
56 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Live and Neutral Conductor Continuity Test
a To ensure that each conductor in the circuit has continuity
b Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
2 Test Method
1 1048766 Switch off the Main switch RCD and MCB
2 1048766 Disconnect all loads
3 1048766 Switch on all switches in the circuit
4 1048766 Disconnect the fusesfinal circuit breakers and close the circuit
5 1048766 Carry out the test as shown in Figure 83
6 1048766 The meter reading value shall be less than 1Ω
57 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
58 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
CONTINUITY TEST
Insulation Resistance Test
i Ensure that there is no leakage current between phase conductors phase and neutral conductors and
phase conductor and earth
ii Test the strength of the cable insulation
iii Test Equipment ndash Insulation Resistance Tester operating voltage is 250VDC or 500VDC
iv Test Method
1 1048766 Switch off main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
59 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
4 1048766 Carry out test as in the Table below
5 1048766 Meter reading value shall be less than 1 Megaohm
60 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
61 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Insulation resitance test
62 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
INSULATION RESISTANCE TEST BETWEEN CONDUCTORS AND OPPOSITE POLARITY
Polarity Testi Ensure that each fuse or single pole control and protection device is connected only in the phase
conductor
ii Intermediate contact of Edison screw lamp holder is connected to the phase conductor
iii Ensure that phase neutral and earth conductors at socket outlets are connected at the correct
terminals
iv Test Equipment ndash Multimeter (Ohm range) or Ohm meter
v Test Method
1 1048766 Switch off Main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in Figure 85
63 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
5 1048766 Test switches and single phase control devices at the phase conductors
6 1048766 Test socket outlet connection sources
7 1048766 Test Edison screw lamp holder connections
8 1048766 Meter reading value shall be less than 1 Ω
64 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Polarity test
65 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Earth Electrode Resistance Testi To test the earth electrode resistance
ii To ascertain the suitability of the location of the electrode
iii To ensure that the electrode is not buried within the resistance area of another electrode
iv Test equipment ndash Earth Resistance Tester
v Test method -
1 1048766 Terminal rsquoErsquo is connected to the electrode to be tested (green conductor)
2 1048766 Terminal lsquoPrsquo is connected to the potential spike (yellow conductor) at a distance of 10
meters from the earth electrode
3 1048766 Terminal lsquoCrsquo is connected to the current spike (red conductor) at a distance of 20 meters
from the earth electrode
Earth Electrode Resistance Measurement Method (Figure 86)
This test must be repeated at least three times to ensure that the reading is not affected by interacting
earthing regions
i Record the first reading (Z1) Example Z1 = 10 Ω
ii Move the voltage spike to a distance of 6 meters from the original position Record the second
reading (Z2 ) Example Z2 = 10 Ω
iii Move the voltage spike to a distance of 6 meters from the original position Record the third
reading (Z3) Example Z3 = 10 Ω
66 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Residual Current Device Testi Ensure that the residual current device (RCD) trips within the set time on the occurrence of current
leakage to earth
ii Test Equipment ndash RCD Tester RCCB Tester
iii Test Method 1
1 1048766 Use the Trip Test Button
2 1048766 Press the trip button found on the RCD to determine if it trips or otherwise This test would
not be able to determine the sensitivity of the RCD nor the time taken for it to trip
iv Test Method 2
i 1048766 Use a RCD Tester
ii This equipment is equipped with a 13A plug which can be connected to a 13A socket outlet
Select the RCD sensitivity to be the same as the sensitivity of the RCD to be tested to
determine if the RCD can trip The time to trip shall not exceed 40 mS
iii 1048766 Test method ndash
a) Position the selection switch in accordance with the sensitivity of the RCD used
Example 100 mA 01 A
b) Position the operations switch to lsquoNo Triprsquo (frac12 Rated mA = 50) connect the 3 pin plug to
the 13A socket outlet
67 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
c) Switch on the 13A socket outlet ndash ensure that the P-N and P-E lights light up
This shows that the polarity is correct (Note if both the lights as above do not light up the test cannot
be continued)
d) Press the test button ndash the reading shows less than 200 mS and simultaneously the lsquotestrsquo light lights
up and the P-N and P-E lights do not light up At that instant the RCD will not trip
e) Move the selection switch to 180o (+ve wave) ndash repeat steps (d) and (e) Move the operations
switch to lsquoTriprsquo (Rated mA = 100)
g) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200mS
h) Move the selection switch to 0o (-ve wave)
i) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
j) The above test is repeated until a near correct reading is obtained
k) Record the test results
l) Change the operations switch to lsquoFast Triprsquo and press the test button ndash RCD will trip within a
time not exceeding 40 millisecond
m) Repeat a number of times at 0o or 180o
On completion of a wiring installation a number of tests on the installation have to be conducted to
ascertain that the wiring circuits and connected appliances are safe for use Prior to carrying out the
tests an inspection has to be done the following tests shall be conducted
i Continuity Test
ii Insulation Resistance Test
iii Polarity Test
iv Earth Electrode Resistance test and
v Residual Current Device Test
821 Continuity Test
There are 3 main types of continuity tests for the final circuits-
i Protection Conductor Continuity Test
ii Final Ring Circuit Conductor Continuity Test
68 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
iii Live and Neutral Conductor Continuity Test
a) Protection Conductor Continuity Test
bull To ascertain that all protection conductors are connected in the correct and effective manner
bull Test equipment ndash Multimeter (Ohm range) or Ohm meter
bull Test Method
1 1048766 Ensure that the main switch RCD and MCB are open circuited (switched off) and all loads are
disconnected
2 1048766 Connected the test leads as in the Figure 81
3 1048766 The meter reading shall be less than 1 Ω
Final Ring Circuit Conductor Continuity Test
bull To ensure that all conductors around the ring circuit have continuity
bull Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
bull Test Method
1 1048766 Disconnect both the supply source live conductors from the MCB the neutral conductor
from the neutral terminals and the earth conductor from the earth terminal in the distribution
fuse box
2 1048766 Connect the test leads as in the Figure 82 (EE)
3 1048766 Repeat the procedure for (L-L) and (N-N)
4 1048766 The meter reading value shall be less than 1 ohm Figure 82 - Final Ring Circuit Conductor
Continuity Test Ohm Meter
Disconnect both the supply source cables from mcbfuse
Take readings at earth conductors of both sources and note resistance readings
Live and Neutral Conductor Continuity Test
1 To ensure that each conductor in the circuit has continuity
2 Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
3 Test Method
1 1048766 Switch off the Main switch RCD and MCB
2 1048766 Disconnect all loads
3 1048766 Switch on all switches in the circuit
4 1048766 Disconnect the fusesfinal circuit breakers and close the circuit
5 1048766 Carry out the test as shown in Figure 83
6 1048766 The meter reading value shall be less than 1 ohm Figure 83 - Live and Neutral
Conductor Continuity Test Ohm Meter
Insulation Resistance Test
69 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
i Ensure that there is no leakage current between phase conductors phase and neutral conductors and
phase conductor and earth
ii Test the strength of the cable insulation
iii Test Equipment ndash Insulation Resistance Tester Operating voltage is 250VDC or 500VDC
iv Test Method
1 1048766 Switch off main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in the Table below
5 1048766 Meter reading value shall be less than 1 Megaohm
Polarity Test
i Ensure that each fuse or single pole control and protection device is connected only in the phase
conductor
ii Intermediate contact of Edison screw lamp holder is connected to the phase conductor
iii Ensure that phase neutral and earth conductors at socket outlets are connected at the correct
terminals
iv Test Equipment ndash Multimeter (Ohm range) or Ohm meter
v Test Method
1 1048766 Switch off Main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in Figure 85
5 1048766 Test switches and single phase control devices at the phase conductors
6 1048766 Test socket outlet connection sources
7 1048766 Test Edison screw lamp holder connections
8 1048766 Meter reading value shall be less than 1 Ω
Earth Electrode Resistance Test
i To test the earth electrode resistance
70 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
ii To ascertain the suitability of the location of the electrode
iii To ensure that the electrode is not buried within the resistance area of another electrode
iv Test equipment ndash Earth Resistance Tester
v Test method -
1 1048766 Terminal rsquoErsquo is connected to the electrode to be tested (green conductor)
2 1048766 Terminal lsquoPrsquo is connected to the potential spike (yellow conductor) at a distance of 10
meters from the earth electrode
3 1048766 Terminal lsquoCrsquo is connected to the current spike (red conductor) at a distance of 20 meters
from the earth electrode E P C Electrode 10 meter 10 meter
Figure 86 ndash Earth Electrode Resistance Measurement Test Equipment
Earth Electrode Resistance Measurement Method (Figure 86)
This test must be repeated at least three times to ensure that the reading is not affected by interacting
earthing regions
i Record the first reading (Z1) Example Z1 = 10 Ω
ii Move the voltage spike to a distance of 6 meters from the original position Record the second
reading (Z2) Example Z2 = 10 Ω
iii Move the voltage spike to a distance of 6 meters from the original position Record the third
reading (Z3)
Example Z3 = 10 Ω
Residual Current Device Test
71 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
i Ensure that the residual current device (RCD) trips within the set time on the occurrence of current
leakage to earth
ii Test Equipment ndash RCD Tester RCCB Tester
iii Test Method 1
1 1048766 Use the Trip Test Button
2 1048766 Press the trip button found on the RCD to determine if it trips or otherwise This test would
not be able to determine the sensitivity of the RCD nor the time taken for it to trip
iv Test Method 2
1048766 Use a RCD Tester
This equipment is equipped with a 13A plug which can be connected to a 13A socket outlet Select the
RCD sensitivity to be the same as the sensitivity of the RCD to be tested to determine if the RCD can
trip The time to trip shall not exceed 40 mS
1048766 Test method ndash
a) Position the selection switch in accordance with the sensitivity of the RCD used
Example 100 mA 01 A
b) Position the operations switch to lsquoNo Triprsquo (frac12 Rated mA = 50) connect the 3 pin plug to
the 13A socket outlet
c) Switch on the 13A socket outlet ndash ensure that the P-N and P-E lights light up This shows that
the polarity is correct (Note if both the lights as above do not light up the test cannot be
continued)
d) Press the test button ndash the reading shows less than 200 millisecond and simultaneously the
lsquotestrsquo light lights up and the P-N and P-E lights do not light up At that instant the RCD will
not trip
e) Move the selection switch to 180o (+ve wave) ndash repeat steps (d) and (e) = 100)
f) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
g) Move the selection switch to 0o (-ve wave)
h) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
i) The above test is repeated until a near correct reading is obtained
j) Record the test results
k) Change the operations switch to lsquoFast Triprsquo and press the test button ndash RCD will trip within a
time not exceeding 40 mS
l) Repeat a number of times at 0o or 180o
72 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 9 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (DC)
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
73 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Start stop button 240Vac 5A 2
9 Filament lamp (Bulb ) 240Vac 40W 3
10 Overload Relay 415V 20A 3
11 Three phase induction motor 5 hp 3
12 Single phase step down transformer 2500VA 1
13 Single core PVC insulated Cable 1mm 2 As required
14 Single core PVC insulated Cable 25mm 2 As required
15 DIN rail 35 mm As required
16 PVC type Cable tray 50 mm x 50 mm As required
17 Cable ties 4 ldquo As required
18 Flexible wires 05 mm As required
19 PVC Connectors 5 A amp 20 A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the schematic
diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a optional exercise
i Simple DOL starter
ii Forward reverse DOL starter
iii Forward Reverse Dahlander motor
iv Three motors operated in sequence by DOL starter operated by manual push
button or time delay relay
74 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
a One loop per-cycle
b Continuous operation in a loop
c optional circuit design to represent the same task
v Only one out of three motors to be operated at a time (quiz)
4 Test the functionality of completed project
LESSON 10 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (AC)
75 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 1
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Lamp point 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
76 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
11 Overload Relay 415V 20A 3
12 Three phase induction
motor
5 hp 3
13 Single core PVC insulated
Cable
1mm 2 As required
14 Single core PVC insulated
Cable
25mm 2 As required
15 DIN rail 35 mm As required
16 PVC type Cable tray 50 mm x 50 mm As required
17 Cable ties 4 ldquo As required
18 Flexible wires 05 mm As required
19 PVC Connectors 5 A amp 20 A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the
schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram optional exercise
4 Simple DOL starter
5 Forward reverse DOL starter
6 Test the functionality of completed project
77 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 1
78 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
cm
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Indicating light 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
11 Overload Relay 415V 20A 3
12 Three phase induction motor 5 hp 3
13 Single phase step down
transformer
2500VA 1
14 Single core PVC insulated
Cable
1mm 2 As required
15 Single core PVC insulated
Cable
25mm 2 As required
16 DIN rail 35 mm As required
17 PVC type Cable tray 50 mm x 50 mm As required
18 Cable ties 4 ldquo As required
19 Flexible wires 05 mm As required
20 PVC Connectors 5 A amp 20 A 240 V As required
21 Single pole MCB 6A 240 V 1
22 Single pole MCB 2A 240 V 1
23 Triple pole MCB 20A 415 V 1
24 Mounting board 30 cm x 40 cm x 3
cm
1
25 Relay cw 11 pin socket 10 A 240 Vac 2
26 Time delay relay 10 A 240 Vac 3
27 Triple pole Contactor 20A 240Vac 3
28 Batten type Lamp holder 240Vac 10 A 3
29 Start stop button 240Vac 10A 2
30 Indicating light (Bulb ) 240Vac 25W 3
31 Overload Relay 415V 20A 1
32 Three phase dahlander type
induction motor
5 hp 1
33 Single phase step down
transformer
24024Vac
2500VA
1
79 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
34 Single core PVC insulated
Cable
1mm 2 As required
35 Single core PVC insulated
Cable
25mm 2 As required
36 DIN rail 35 mm As required
37 PVC type Cable tray 50 mm x 50 mm As required
38 Cable ties 4 ldquo As required
39 Flexible wires 075 mm As required
40 PVC Connectors 5 A amp 20 A 240 V As required
41 Terminal block 20A 240Vac As required
Procedures
5 Identify each component according to specification and quantity required from the schematic
diagram attached
6 Test the functionality of each component by using multi-meter or power supply whichever
applicable
7 Wire component according to circuit diagram
8 Three motors operated in sequence by DOL starter operated by manual push button or time
delay relay
a One loop per-cycle
b Continuous operation in a loop
c optional circuit design to represent the same task
d Only one out of three motors to be operated at a time (quiz)
9 Test the functionality of completed project
80 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
BASIC DESIGN INDUSTRIAL MOTOR CONTROL (SEQUENCE CONTROL)
THREE PHASE INDUCTION MOTOR OPERATED IN SEQUENCE BY DIRECT ON LINE
STARTER
LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
81 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
82 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Lcd lamp indicator 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
11 Overload Relay 415V 20A 3
12 Three phase induction motor 5 hp 3
13 Single phase step down transformer 2500VA 1
14 Single core PVC insulated Cable 1mm 2 As required
15 Single core PVC insulated Cable 25mm 2 As required
16 DIN rail 35 mm As required
17 PVC type Cable tray 50 mm x 50 mm As required
18 Cable ties 4 ldquo As required
19 Flexible wires 1 mm Oslash As required
20 PVC Terminal block 10A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the schematic
diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a optional exercise
i Forward Reverse dahlander motor
4 Test the functionality of completed project
83 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
THREE PHASE DAHLANDER TYPE INDUCTION MOTOR OPERATED FORWARD AND
REVERSE OPERATION BY DIRECT ON LINE STARTER
84 ndash 99EASYTECH ENTERPRISE
LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
Introduction
If a motors windings are connected in the star configuration any two phases will be in series across
the supply and hence the line current will be smaller(by 577) than if the windings were connected in
the delta arrangement
Hence larger-type motors with heavy starting currents are first connected in star and then when the
starting currents fall in delta This of course means that all six of the ends of the windings must be
brought to terminations outside the casing (Fig 833)
EZTECH
EZTECH ELECTRICAL INSTALLATION GUIDE
The automatic version of this starter incorporates a timing relay which automatically changes the
connections from star to delta Figs 834 and 835 show the wiring and schematic diagrams for a star
delta starter
Objectives
1 Identify component and the specification
2 Design forward reverse star delta starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
2 ndash 99EASYTECH ENTERPRISE
REV -C
LEGENDMCCB Moulded Case Circuit BreakerTOR Thermal Over Load RelayFOW-C Mains Forward ContactorREV-C Mains Reverse ContactorDC Delta ContactorSC Star ContactorS-SW Mains Selector Switch
SC
V2
W2
U2
DC
V1
W1
U1
TOR
TOR
FOW-C
30A MCCB
TOR
MAIN CIRCUIT FORWARD REVERSE STAR DELTA
RYBN S
-SW
3 PHASEINDUCTION MOTOR
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Relay 10 A 240V 3
5 Triple pole Contactor
6 cw NO NC auxiliary contact
240Vac 20 A 4
7 Overload Relay 415 V 1
8 LED indicator 240vac 5 A 4
9 Start stop button 240Vac 5A 2
10 DIN rail 35 mm As required
11 Flexible wires 1 mm As required
12 Single core PVC insulated
wire
25 mm As required
13 Terminal block 20 A As required
14 Squirrel cage motor 5kW 1
15 5 pin plug and socket 415V 20A 1
16 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
3 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
a Manual star delta
b Manual Forward reverse star delta starter
c Automatic star delta starter
d Automatic Forward reverse star delta starter
4 Test the functionality of completed project
4 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
Objectives
1 Identify component and the specification
2 Design auto transformer starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
5 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Autotransformer starter is used to start a 3 phase induction motor that has a rating between 10 to 15 hp
6 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Autotransformer set 10Kw 415 V 50 Hz 1
5 Triple pole Contactor 240Vac 4
6 Batten type Lamp holder 240 Vac 105 A 4
7 Start stop button 240Vac 10A 4
8 Filament lamp (Bulb ) 240Vac 40W 4
9 DIN rail 35 mm As required
10 Flexible wires 1 mm As required
7 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
11 Single core PVC insulated
wire
25 mm As required
12 Terminal block 20 A As required
13 Squirrel cage motor 10kW 1
14 5 pin plug and socket 415V 20A 1
15 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a open transient autotransformer starter
b close transient autotransformer starter
c Forward reverse autotransformer starter
4 Test the functionality of completed project
8 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
Objectives
1 Identify component and the specification
2 Design rotor resistance starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
9 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Rotor Resistor set 10kW 1
5 Triple pole Contactor 240Vac 20A 4
6 Indicating light 240vac 5 A 4
7 Start stop push button 240Vac 5A 4
8 DIN rail 35 mm As required
9 Flexible wires 1 mm 2 As required
10 Single core PVC insulated wire 25 mm 2 As required
11 Terminal block 20 A As required
12 Slip Ring motor 10kW 1
13 5 pin round 3 phase socket 415V 20A 1
14 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
10 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
4 Test the functionality of completed project
a Dead circuit test b Life circuit test
5 Measure starting and running Amps
LESSON 16
TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
An installation in general will suffer damage
Damage usually occurs on the electric motor control as follows
1 Damage to the main circuit
2 Damage to the control circuit
The cause of the damage
i Overcurrent overload short circuit
ii Leakage current to ground
iii Equipment malfunction
iv The main control circuit
a Trip of main circuit protection devices fire
b Defect of motor terminal such as short circuit fire loose
v The control circuit is not functioning -
a contactor relay relay time overload relay does not work damaged burned
b Loose cable connection disconnected
Detecting and Repairing Damage
Examples of damage are as follows
i Motor does not work
ii Motor function and overload relay trips
iii Motor function but only partially functional control circuit
Methods of detecting damage
Among the known methods necessary to detect damage are as follows
1 Turn off the electricity at the main switch (main switch) in order to avoid any danger during the
work carried out to detect damage
2 Check all the protective gear that controls the motor control main circuit
11 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
3 Make sure the damage function control circuit
4 Check the control circuit according to the schematic circuit diagram of the motor control
5 Check the operation of the control circuit
Note
Use wiring that has been installed on the SYSTEM OF MOTOR CONTROL BOARD by Forward
Reverse control circuit for Star Delta to test and look for damage
SELF-ASSESSMENT QUESTIONS
1 (a) Explain what is meant by the term lsquoback emfrsquo in a motor
(b) Outline the basic differences between series shunt and compound wound dc motors
2 (a) With the aid of diagrams explain how the speed of series shunt and compound-wound motors
may be controlled
(b) A 440V dc shunt-wound motor has a field resistance of 200R and an armature resistance of 06 R
When its speed is 20 rev d second the current drawn from the supply is 122A Calculate its back
emf at this speed If the speed were decreased to 19 revssecond the field flux remaining unchanged
calculate the new back emf and the new armature current
3 A load of 64 kW at 240 V is supplied from the terminals of a shunt-wound dc generator The field
resistance is 180 A Calculate the armature current
4 (a) Explain with the aid of a diagram how a rotating magnetic field may be
(b) What is meant by lsquosynchronous speedrsquo
Calculate the synchronous obtained speed of a 12 pole motor if the supply frequency is 50Hz
5 (a) Explain the action of a synchronous motor
(b) What methods are available to start a synchronous motor Explain with diagrams
6 (a) Explain the action of a cage induction motor
(b) What is meant by the term lsquosliprsquo
Calculate the percentage slip of a six pole induction motor running at 162 revssecond from a 50 Hz
supply
7 Describe with sketches three different ways of starting a single-phase induction motor
12 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
8 Explain with the aid of a sketch the action of a three-phase DOL starter
What are dashpots used for How are remote start and stop buttons connected
9 A I0 kW 240V 50Hz single-phase cage rotor induction motor is 85efficient and has a PF of 068
lagging Calculate the motor current and the value of capacitor required to raise the PF to 093
lagging
10 Calculate the torque developed by an 18 kW four-pole induction motor run at 35 slip from a
50Hz supply
APPENDIX 1
13 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 11
14 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 111
Attachment Reference
httpswwwtlc-directcoukBook621htm
httpwwwstgovmyindexphpms
15 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
33 Use of Minimum Cross Sectional Area Rating of Wiring Conductors
The following are the minimum cross sectional areas of conductors based on their applications-
34 Use of Protection Conductor Minimum Cross Sectional Area Rating
In Comparison with Phase Conductor Cross Sectional Area
The following table shows the protection conductor minimum cross sectional area in comparison
with the phase conductor cross sectional area
Use of Minimum Cross Sectional Area Rating of Wiring Conductors
The following are the minimum cross sectional areas of conductors based on their applications-
Use of Protection Conductor Minimum Cross Sectional Area Rating
In Comparison with Phase Conductor Cross Sectional Area
The following table shows the protection conductor minimum cross sectional area in comparison
with the phase conductor cross sectional area
Functions and Colour Identification of Non Flexible CablesThe following table shows the functions and colour identification of non flexible cables
12 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Flexible Cables
i Flexible cables of cross sectional area less than 40 mm2 are used in installations for electrical
accessories such as ceiling roses lamp fixtures or attachments socket plugs for mobile
appliances etc
ii Flexible cables shall not be used for permanent wiring
iii Flexible cables for the permanent use of electrical appliances should not exceed 3 meters in
length
37 Functions and Colour Identification of Flexible Cables
Conductor Insulation and Types of WiringVarious material and insulation layers are used for conductor protection Cable selection in
accordance to insulation layers must be done correctly for the type of the wiring installation as
shown in the table below
Functions and Colour Identification of Non Flexible CablesThe following table shows the functions and colour identification of non flexible cables
3 SELECTION OF WIRING ACCESSORIES
i All wiring accessories to be used have to be of those approved by the Energy Commission and
labeled with labels issued by SIRIM For all wiring using UPVC conduits -
13 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
a) Switches socket outlets 3 pin plugs ceiling roses connectors sockets ndash construction material shall
be of polycarbonate type
iii For all wiring using metal conduits - Switches socket outlets and connectors ndash construction
material shall be of metal clad type and All accessories shall be effectively earthed
iv Switch fuse used in single phase installations shall have the fuse permanently connected and not
move with the fuse
v Fuse switch used in 3 phase domestic installations also has fuse and switch The fuse connector is
installed together to allow the fuse to move simultaneously with the switch
vi Lamp
a) Fluorescent lamps using magnetic ballasts (watt loss not exceeding 6 watts) shall be
equipped with dry paper type capacitor
b) Fluorescent lamps using electronic ballasts or high frequency electronic ballasts do not
need capacitors
c) Outdoor domestic lamp installations shall use weather proof and water proof lamps
d) Submerged light installations (example in swimming pools fountains etc) shall have water
proof lamps with a voltage not exceeding 12 Volt AC
vii Electric water heaters is divided into 2 types namely
1 instantaneous water heaters and
2 stored water heaters (storage tank type)
a) Instantaneous water heaters shall be equipped with a 2 pole control switch and its own
residual current device
b) Storage water heaters (storage tank type) shall be installed with an
Water heaters exceeding 3kW shall be permanently connected to a 20A30A rated circuit
breakerfuse with an isolator switch and residual current device
viii Electric cookers exceeding 3kW shall have its own circuit connected permanently to a 30A rated
circuit breaker or fuse with an isolator switch and cooker control unit incorporated with a 13A socket
outlet Two or more cooker appliances may be installed in the same room within a distance of 2
meters
ix Electric motors (fence gate air conditioners fountains swimming pools fish ponds water
pumps) exceeding 373W but not exceeding 2238W shall be connected permanently to a 20A30A
rated circuit breakerfuse together with an isolator motor starter and 15A socket outlet
14 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
The motor starter shall be of Direct-On-Line type with the appliance together with the contactor
overload relay and on-off control The circuit breakerfuse which controls the motor circuit shall be
capable of withstanding the starting current of the motor
x Electric bells ndash the circuit shall have a push button switch and a ACDC transformer
xi Ceiling fans shall conform to clause 21101 of the MS 12192002 standard with regards to test on
the suspension system of ceiling fans
EARTHING OF ELECTRICAL INSTALLATIONS51 Earthing
Earthing is a connection system between the metallic parts of an electrical wiring system and the
general mass of the earth This will provide an easy path with a low impedence or resistance to earth to
enable the protection system to operate effectively It will thus ensure safety to human
beingsconsumers from the dangers of electric shocks if earth leakage currents are present In general
an electrical installation is earthed because of -
i Safety reasons
ii Protection system requirements
iii Need to limit over voltages
iv Need to provide a path for electrical discharge
v Legal requirements
52 Classification of Earthing
Generally earthing can be divided into 2 parts namely -
i System Earthing
a To isolate the system under fault conditions
b To limit the potential difference between conductors which are not insulated in an area
c To limit the occurrence of over voltages under various conditions
ii Equipment Earthing
Equipment earthing is undertaken to protect human beingsconsumers If a live source comes into
contact with the equipment body electrical energy will flow to the earth without flowing through the
human being consumerrsquos body This is because of the fact that the human body has a greater
resistance compared with the resistance to earth
53 Types and Functions of Earthing Accessories
Earthing accessories are as follows -
i Earthing Electrode
Copper jacketed steel core rods are used as electrodes for domestic wiring
ii Equipotential Bonding
15 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
This is the conductor which is connected between the consumer earthing point and the exposed
metallic part The minimum cable size for this purpose is 10 mm2
iii Protection Conductor
This is the conductor which connects the consumer earthing point with other parts of the installation
which needs earthing Its size is as follows-
a) Same size as the phase cable up to a size of 16mm2
b) 16 mm2 if the phase cable size is between 16 mm2 and 35 mm2
c) Half the size of the phase cable if the size of the phase cable exceeds 35 mm2
54 Earthing Arrangements Using a TT System
i The first alphabet indicates the earthing arrangements from the supply side
ii The second alphabet indicates the earthing arrangement in the consumerrsquos installation
T ndash first Indicates that the supply system has its own earthing arrangements
T ndash second Indicates that all metallic frames of the electrical appliances etc are connected directly to
earth
Parts that are Required to be Earthed
i All metallic structures in the wiring system (non current carrying) such as metallic covers conduits
ducts the armour of catenary wires etc
ii A secondary winding point in a transformer and
iii Frame of metal roof truss
56 Parts that are not Required to be Earthed
i Short isolated metallic parts for mechanical protection of cables which have non metallic sheaths
other than conduits which are connected at entry points between the building and conduits which
protect discharge lamp cables
ii Cable clips for installing cables
iii Metallic covers for lamps
16 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
iv Small metallic parts such as screws and name plates which are isolated by means of insulation
v Metallic lamp parts for filament lamps in water proof floors
57 Termination to Earth
The termination to earth is done as shown in Figure 72
Earth Electrode Resistance
The maximum permitted earth electrode resistance for different types of installations is as shown in
the Table below
Earth electrode for installations protected by RCDs of sensitivity 100mA 10 Ω
Lightning arrestor earth electrode 10 Ω
Legal Requirements
i Sub regulation 12(1) and 12(2) of the Electricity Regulations 1994 state that any electrical wiring in
an installation shall be under the immediate supervision of a Wireman with Single Phase Restriction or
Three Phase Restriction Upon completion the Wireman shall certify a Supervision and Completion
Certificate
ii Sub regulation 13(1) and 13 (2) of the Electricity Regulations 1994 state that the installation shall
be tested by a Wireman with Single Phase Restriction or a Wireman with Three Phase Restriction
authorized to test any installation and who shall certify a Test Certificate for the installation
iii Sub regulation 14(1) of the Electricity Regulations 1994 states that the Supervision and
Completion Certificate and the Test Certificate as in regulations 12 and 13 shall be in Forms G and H
respectively as prescribed in the First Schedule
17 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
4 SAFETY REQUIREMENTS FOR ELECTRICAL WIRING WORKS IN RESIDENTIAL BUILDINGS
61 Safety Requirements
Safety requirements for electrical wiring works have to be followed to eliminate any accidents which
can result in physical damage or loss of life or property Failure to meet the safety regulations may
result in workers consumers or the public being inflicted with electrical shocks
In addition to this safety steps will also encourage workers or electricity consumers who are
disciplined and who always give importance to safety
62 Safety Steps
Safety requirements have to be followed whenever electrical works are undertaken in a residential
building
i Personal Safety
a Use suitable personal protection equipment as needed such as safety shoes gloves safety helmet
etc when at the work place
b Use safety clothing suitable for the work to be undertaken
c Do not wear jewellery or decorative items such as rings watches chains etc while carrying out
electrical works
ii Safety at the Work Place
a Acquire knowledge about the dangers of electrical works that is to be undertaken and how to deal
with those dangers
b Always adhere to the safety regulations which have been set for the work place
c Ensure that the electricity supply is switched off before carrying out the works
d Acquire the needed knowledge and practice a cautious and calm attitude while working ensure
cleanliness in and around fellow workers
e While working at elevated places the worker should always use suitable equipment such as wooden
or aluminium ladders iron scaffoldings or platforms safety belts or other equipment needed to ensure
that the work can be undertaken safely
f Use electrical equipment which is operational and safe to be used and ensure that the supply for it is
being supplied through a residual current device (RCD) with a sensitivity of 30 mA
g Ensure that exposed temporary supply electrical cables have mechanical protection
h If inflammable or corrosive material is present necessary safety steps have to be undertaken as
required by the relevant safety regulations
63 Dangers of Electrical Shocks
i Electrical Shock
Electrical shocks can occur due to direct or indirect contact
a Direct Contact
18 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Direct contact occurs when the worker or consumer receives an electrical shock on touching directly a
live conductor or cable
b Indirect Contact
Here the electric shock occurs due to contact with a part which is connected to the electrical
installation and not to a direct contact with a live cable or conductor possibly due to damages in the
appliance or insulation resulting in leakages of current
Why Electric Shocks Occura Unsafe Work Method or Action Undertaking Electrical Work Without Disconnecting the
Supply
Maintenance or circuit testing work done without disconnecting the supply will have a high possibility
of electrical shocks occurring
bull Not Following Safe Work Procedures
To eliminate the occurrence of electrical shocks each worker has to always follow safe work
procedures which are set by regulations and standards
b Defects in the Electrical System
i Leakage Current
Leakage currents or earth leakage currents can result in the metallic frames becoming live and
energised This can give rise to the danger of electrical shock to the worker consumer or the public if
they hold or come into contact with the metallic frame
ii Exposed Conductor or Disconnected Cable
Exposed conductors or cables which are broken and are alive (energised) can result in electrical shock
when touched The supply source must be immediately isolated or switched off and a report must be
made to the responsible entity
64 First Aid and Basic Pulmonary Resuscitation
i First Aid
First aid is the initial assistance given to a person who has met with an accident is sick or is injured to
prevent the condition of the victim from becoming more serious while awaiting the arrival of the
paramedics (ambulance) or before being brought to the hospital
i Pulmonary Resuscitation
Pulmonary resuscitation has to be undertaken to assist the victim who has breathing difficulties as a
result of being drowned receiving an electrical shock etc Pulmonary resuscitation has to be carried
out in accordance to the correct method as stated in the first aid manuals issued by accredited first aid
bodies
ii First Aid Box
19 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
A first aid box has to be provided by the building owner construction site supervisor or brought
personally by the worker under the supervision of the responsible person
65 Training Programme
The management shall conduct periodic training programmes for the workers with regards to work
safety on aspects including the following -
i Dangers of electrical work being undertaken and how to control those dangers
ii The safety regulations set for the work place and
iii First aid procedures
66 Fire Prevention
Fire Extinguisher A suitable functioning fire extinguisher to control fires has to be made available at
the work place at all times
67 Competent Person
The Electricity Regulations 1994 require that all electrical work has to be undertaken by or under the
direct supervision of a competent person registered with the Energy Commission Besides that the
electrical contractor undertaking the electrical work has also to be registered with the Energy
Commission The installation owner thus has to ensure that the appointed electrical contractor is
registered with the Energy Commission and that the registration is still valid
INSTALLATION CIRCUITS AND SYSTEMS1 Block diagrams
These show using squares rectangles etc the sequence of a system without too much technical detail
eg Figures 1517 and 1526
2 Layout diagrams
These are very similar to block diagrams but they indicate more technical detail and tend to show
items in their correct geographical location (eg Figures 1518 and 1519)
3 Circuitschematic
These show how a circuit functions and takes no account of exact locations of terminals or equipment
(eg Figures 1528 1529 1532 1534 etc)
4 Wiring diagram
These indicate how a circuit or system is physically wired (eg Figures 152 154 156 etc)
Most induction motors are started directly on line but when very large motors are started that way
they cause a disturbance of voltage on the supply lines due to large starting current surges To limit the
starting current surge large induction motors are started at reduced voltage and then have full supply
voltage reconnected when they run up to near rotated speed Two methods are used for reduction of
starting voltage are star delta starting and auto transformer stating
20 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Working Principal of Star-Delta Starter
This is the reduced voltage starting method Voltage reduction during star-delta starting is achieved by
physically reconfiguring the motor windings as illustrated in the figure below During starting the
motor windings are connected in star configuration and this reduces the voltage across each winding 3
This also reduces the torque by a factor of three After a period of time the winding are reconfigured as
delta and the motor runs normally
StarDelta starters are probably the most common reduced voltage starters They are used in
an attempt to reduce the start current applied to the motor during start as a means of reducing the
disturbances and interference on the electrical supply
Traditionally in many supply regions there has been a requirement to fit a reduced voltage
starter on all motors greater than 5HP (4KW) The StarDelta (or WyeDelta) starter is one of the
lowest cost electromechanical reduced voltage starters that can be applied
The StarDelta starter is manufactured from three contactors a timer and a thermal overload
The contactors are smaller than the single contactor used in a Direct on Line starter as they are
controlling winding currents only The currents through the winding are 1root 3 (58) of the
current in the line
There are two contactors that are close during run often referred to as the main contractor and
the delta contactor These are AC3 rated at 58 of the current rating of the motor The third
contactor is the star contactor and that only carries star current while the motor is connected in star
The current in star is one third of the current in delta so this contactor can be AC3 rated at one
third (33) of the motor rating
Star-delta Starter Consists following units
1) Contactors (Main star and delta contactors) 3 Norsquos (For Open State Starter) or 4 Norsquos (Close
Transient Starter)
2) Time relay (pull-in delayed) 1 No
3) Three-pole thermal over current release 1No
4) Fuse elements or automatic cut-outs for the main circuit 3 Nos
5) Fuse element or automatic cut-out for the control circuit 1No
Power Circuit of Star Delta Starter
1 The main circuit breaker serves as the main power supply switch that supplies electricity to the
power circuit
2 The main contactor connects the reference source voltage R Y B to the primary terminal of the
motor U1 V1 W1
21 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
3 In operation the Main Contactor (KM3) and the Star Contactor (KM1) are closed initially and
then after a period of time the star contactor is opened and then the delta contactor (KM2) is
closed The control of the contactors is by the timer (K1T) built into the starter The Star and Delta
are electrically interlocked and preferably mechanically interlocked as well In effect there are
four states
4 The star contactor serves to initially short the secondary terminal of the motor U2 V2 W2 for the
start sequence during the initial run of the motor from standstill This provides one third of DOL
current to the motor thus reducing the high inrush current inherent with large capacity motors at
startup
5 Controlling the interchanging star connection and delta connection of an AC induction motor is
achieved by means of a star delta or wye delta control circuit The control circuit consists of push
button switches auxiliary contacts and a timer
Control Circuit of Star-Delta Starter (Open Transition)
1 The ON push button starts the circuit by initially energizing Star Contactor Coil (KM1) of star
circuit and Timer Coil (KT) circuit
2 When Star Contactor Coil (KM1) energized Star Main and Auxiliary contactor change its
position from NO to NC
3 When Star Auxiliary Contactor (1)( which is placed on Main Contactor coil circuit )became
NO to NC itrsquos complete The Circuit of Main contactor Coil (KM3) so Main Contactor Coil
energized and Main Contactorrsquos Main and Auxiliary Contactor Change its Position from NO
To NC This sequence happens in a friction of time
4 After pushing the ON push button switch the auxiliary contact of the main contactor coil (2)
which is connected in parallel across the ON push button will become NO to NC thereby
providing a latch to hold the main contactor coil activated which eventually maintains the
control circuit active even after releasing the ON push button switch
5 When Star Main Contactor (KM1) close its connect Motor connects on STAR and itrsquos
connected in STAR until Time Delay Auxiliary contact KT (3) become NC to NO
6 Once the time delay is reached its specified Time the timerrsquos auxiliary contacts (KT)(3) in
Star Coil circuit will change its position from NC to NO and at the Same Time Auxiliary
contactor (KT) in Delta Coil Circuit(4) change its Position from NO To NC so Delta coil
energized and Delta Main Contactor becomes NO To NC Now Motor terminal connection
change from star to delta connection
7 A normally close auxiliary contact from both star and delta contactors (5amp6)are also placed
opposite of both star and delta contactor coils these interlock contacts serves as safety
switches to prevent simultaneous activation of both star and delta contactor coils so that one
22 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
cannot be activated without the other deactivated first Thus the delta contactor coil cannot be
active when the star contactor coil is active and similarly the star contactor coil cannot also
be active while the delta contactor coil is active
8 The control circuit above also provides two interrupting contacts to shutdown the motor
The OFF push button switch break the control circuit and the motor when necessary The
thermal overload contact is a protective device which automatically opens the STOP Control
circuit in case when motor overload current is detected by the thermal overload relay this is to
prevent burning of the motor in case of excessive load beyond the rated capacity of the motor
is detected by the thermal overload relay
9 At some point during starting it is necessary to change from a star connected winding to a
delta connected winding Power and control circuits can be arranged to this in one of two
ways ndash open transition or closed transition
What is Open or Closed Transition Starting
(1) Open Transition Starters
Discuss mention above is called open transition switching because there is an open state between
the star state and the delta state
In open transition the power is disconnected from the motor while the winding are reconfigured via
external switching
When a motor is driven by the supply either at full speed or at part speed there is a rotating
magnetic field in the stator This field is rotating at line frequency The flux from the stator field
induces a current in the rotor and this in turn results in a rotor magnetic field
When the motor is disconnected from the supply (open transition) there is a spinning rotor within
the stator and the rotor has a magnetic field Due to the low impedance of the rotor circuit the time
constant is quite long and the action of the spinning rotor field within the stator is that of a
generator which generates voltage at a frequency determined by the speed of the rotor When the
motor is reconnected to the supply it is reclosing onto an unsynchronized generator and this result
in a very high current and torque transient The magnitude of the transient is dependent on the
phase relationship between the generated voltage and the line voltage at the point of closure can
be much higher than DOL current and torque and can result in electrical and mechanical damage
Open transition starting is the easiest to implement in terms or cost and circuitry and if the timing
of the changeover is good this method can work well In practice though it is difficult to set the
necessary timing to operate correctly and disconnectionreconnection of the supply can cause
significant voltagecurrent transients
In Open transition there are Four states
23 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 OFF State All Contactors are open
2 Star State The Main [KM3] and the Star [KM1] contactors are closed and the delta [KM2]
contactor is open The motor is connected in star and will produce one third of DOL torque at one
third of DOL current
3 Open State This type of operation is called open transition switching because there is an
open state between the star state and the delta state The Main contractor is closed and the Delta
and Star contactors are open There is voltage on one end of the motor windings but the other end
is open so no current can flow The motor has a spinning rotor and behaves like a generator
4 Delta State The Main and the Delta contactors are closed The Star contactor is open The
motor is connected to full line voltage and full power and torque are available
(2) Closed Transition StarDelta Starter
There is a technique to reduce the magnitude of the switching transients This requires the use of a
fourth contactor and a set of three resistors The resistors must be sized such that considerable
current is able to flow in the motor windings while they are in circuit
The auxiliary contactor and resistors are connected across the delta contactor In operation just
before the star contactor opens the auxiliary contactor closes resulting in current flow via the
resistors into the star connection Once the star contactor opens current is able to flow round
through the motor windings to the supply via the resistors These resistors are then shorted by the
delta contactor If the resistance of the resistors is too high they will not swamp the voltage
generated by the motor and will serve no purpose
In closed transition the power is maintained to the motor at all time This is achieved by
introducing resistors to take up the current flow during the winding changeover A fourth
contractor is required to place the resistor in circuit before opening the star contactor and then
removing the resistors once the delta contactor is closed These resistors need to be sized to carry
the motor current In addition to requiring more switching devices the control circuit is more
complicated due to the need to carry out resistor switching
In Close transition there are Four states
1 OFF State All Contactors are open
2 Star State The Main [KM3] and the Star [KM1] contactors are closed and the delta [KM2]
contactor is open The motor is connected in star and will produce one third of DOL torque at one
third of DOL current
Star Transition State The motor is connected in star and the resistors are connected across the
delta contactor via the aux [KM4] contactor
24 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Closed Transition State The Main [KM3] contactor is closed and the Delta [KM2] and Star
[KM1] contactors are open Current flows through the motor windings and the transition resistors
via KM4
Delta State The Main and the Delta contactors are closed The transition resistors are shorted out
The Star contactor is open The motor is connected to full line voltage and full power and torque
are available
Effect of Transient in Starter (Open Transient starter)
It is Important the pause between star contactor switch off and Delta contactor switch is on correct
This is because Star contactor must be reliably disconnected before Delta contactor is activated It
is also important that the switch over pause is not too long
For 415v Star Connection voltage is effectively reduced to 58 or 240v The equivalent of 33
that is obtained with Direct Online (DOL) starting
If Star connection has sufficient torque to run up to 75 or 80 of full load speed then the motor
can be connected in Delta mode
When connected to Delta configuration the phase voltage increases by a ratio of V3 or 173 The
phase currents increase by the same ratio The line current increases three times its value in star
connection
During transition period of switchover the motor must be free running with little deceleration
While this is happening ldquoCoastingrdquo it may generate a voltage of its own and on connection to the
supply this voltage can randomly add to or subtract from the applied line voltage This is known as
transient current Only lasting a few milliseconds it causes voltage surges and spikes Known as
a changeover transient
Size of each part of Star-Delta starter
(1) Size of Over Load Relay
For a star-delta starter there is a possibility to place the overload protection in two positions in the
line or in the windings
Overload Relay in Line
In the line is the same as just putting the overload before the motor as with a DOL starter
The rating of Overload (In Line) = FLC of Motor
Disadvantage If the overload is set to FLC then it is not protecting the motor while it is in delta
(setting is x1732 too high)
Overload Relay in Winding
25 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
In the windings means that the overload is placed after the point where the wiring to the contactors
are split into main and delta The overload then always measures the current inside the windings
The setting of Overload Relay (In Winding) =058 X FLC (line current)
Disadvantage We must use separate short circuit and overload protections
(2) Size of Main and Delta Contractor
1 There are two contactors that are close during run often referred to as the main contractor and
the delta contactor These are AC3 rated at 58 of the current rating of the motor
Size of Main Contactor= IFL x 058
(3) Size of Star Contractor
The third contactor is the star contactor and that only carries star current while the motor is
connected in star The current in star is 1 radic3= (58) of the current in delta so this contactor can
be AC3 rated at one third (33) of the motor rating
Size of Star Contactor= IFL x 033
Motor Starting Characteristics of Star-Delta Starter
Available starting current 33 Full Load Current
Peak starting current 13 to 26 Full Load Current
Peak starting torque 33 Full Load Torque
Advantages of Star-Delta starter
The operation of the star-delta method is simple and rugged
It is relatively cheap compared to other reduced voltage methods
Good TorqueCurrent Performance
It draws 2 times starting current of the full load ampere of the motor connected
Disadvantages of Star-Delta starter
Low Starting Torque (Torque = (Square of Voltage) is also reduce)
Break In Supply ndash Possible Transients
Six Terminal Motor Required (Delta Connected)
It requires 2 set of cables from starter to motor
It provides only 33 starting torque and if the load connected to the subject motor requires higher
starting torque at the time of starting than very heavy transients and stresses are produced while
changing from star to delta connections and because of these transients and stresses many
electrical and mechanical break-down occurs
26 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
In this method of starting initially motor is connected in star and then after change over the motor
is connected in delta The delta of motor is formed in starter and not on motor terminals
High transmission and current peaks When starting up pumps and fans for example the load
torque is low at the beginning of the start and increases with the square of the speed When
reaching approx 80-85 of the motor rated speed the load torque is equal to the motor torque and
the acceleration ceases To reach the rated speed a switch over to delta position is necessary and
this will very often result in high transmission and current peaks In some cases the current peak
can reach a value that is even bigger than for a DOL start
Applications with a load torque higher than 50 of the motor rated torque will not be able to start
using the start-delta starter
Low Starting Torque The star-delta (wye-delta) starting method controls whether the lead
connections from the motor are configured in a star or delta electrical connection The initial
connection should be in the star pattern that results in a reduction of the line voltage by a factor of
1radic3 (577) to the motor and the current is reduced to 13 of the current at full voltage but the
starting torque is also reduced 13 to 15 of the DOL starting torque
The transition from star to delta transition usually occurs once nominal speed is reached but is
sometimes performed as low as 50 of nominal speed which make transient Sparks
Features of star-delta starting
1 For low- to high-power three-phase motors
2 Reduced starting current
3 Six connection cables
4 Reduced starting torque
5 Current peak on changeover from star to delta
6 Mechanical load on changeover from star to delta
Application of Star-Delta Starter
The star-delta method is usually only applied to low to medium voltage and light starting
Torque motors
The received starting current is about 30 of the starting current during direct on line start and the
starting torque is reduced to about 25 of the torque available at a DOL start This starting
method only works when the application is light loaded during the start If the motor is too heavily
27 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
loaded there will not be enough torque to accelerate the motor up to speed before switching over
to the delta position
LESSON 1 WIRING SYSTEM OF SINGLE PHASE DISTRIBUTION BOARD
Introduction
28 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
29 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
30 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
31 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 2 WIRING SYSTEM OF SINGLE PHASE LIGHTING CIRCUIT Introduction
Objectives
1 Identify component and the specification
2 Wire component according to the schematic diagram
3 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Wiring bay Perforated metal 180 cm x 180 cm 1
2 Cut out fuse 63 A 240 V 1
3 Neutral link 1
4 Single pole one way switch cw
switch box
5A 240Vac 4
5 single pole two way switch cw
switch box
5A 240Vac 2
6 RCCB In = 40 A Tripping current
100mA240 Vac 50 Hz
1
7 Main switch 32 A 240V 1
8 kWatthour meter 40 A 240 Vac 1
9 Single pole MCB 6A 240 Vac 1
10 Self tapping Wood screw As required
11 DIN rail 35 mm width As required
32 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
12 PVC trunking 50 mm x 50 mm As required
13 Terminal blocks 5 A As required
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
1 One way switch to control one lamp
2 One way switch to control two lamps
3 Two of two way switch to control one lamp
4 Two of single pole two way switch and one of an intermediate switch to control one
lamp
5 One unit of ceiling fan and fan regulator to be controlled by one way switch
4 Test the functionality of completed project
LESSON 3ndash WIRING SYSTEM OF SINGLE PHASE POWER CIRCUIT Introduction
33 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
34 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify types of component and its specification
2 Wire component according to the schematic diagram given
3 Test the functionality of the circuit dead circuit test life circuit test
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board Perforated Metal 1
2 kWh meter 240 V 40 A 1
3 Socket outlet 13A 240Vac 4
4 RCCB 40A Trip Amps
30mA240 Vac
1
5 3 pin socket 240Vac 13A 4
6 Single pole MCB 20A 240 V 2
7 DOL starter 1 kW 240Vac 2
8 1 phase induction motor 2Hp 240 Vac 1
9 Cooker control unit 4kW 240Vac 1
10 Water heater point 4kW 240 Vac 1
11 DIN rail 35 mm As required
12 PVC casing 20mm As required
13 Flexible wires 05 mm As required
14 Terminal block 10 A As required
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Wire two unit of 13 A socket outlet in radial circuit
3 Wire four units of 13 A socket outlet in ring circuit
4 Wire one unit DOL starter for air-conditioner point
5 Wire one unit of cooker control unit point
6 Wire one unit of water heater point
7 Test the functionality of each component by using mmeter or power supply whichever
applicable
8 Wire component according to circuit diagram
9 Test the functionality of completed project dead circuit test life circuit test
Note
35 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Ensure that the correct rating of protection device and size of wire used
LESSON 4ndash CONDUIT BENDING AND TRUNKING FABRICATION TECHNIQUE
Common fitting used in an industrial wiring
Cutting and threading the condute
36 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
37 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
38 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify conduit fitting and the specification
2 Measure and Cut steel conduit according to specified dimension
3 Bend and fabricate conduit at 45 90 according to layout diagram
4 Wire component according to the schematic diagram
5 Test the functionality of the circuit
39 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Conduit Bender Oslash 19 mm ( frac34 ldquo) 1
2 Measuring Tape 3 metre 1
3 Hacksaw frame and blade 30cm 1
4 Conduit cutter 1
5 Pipe Vise 1
6 Pipe Wrench 1
7 Ratchet Dies 20 mm 1
8 Metal trunking 50 mm x 50 mm 1
9 GI conduit 20mm 1
10 End box 20 mm 1
11 Flexible wires 05 mm As required
12 Connectors 5 A As required
13 Single core PVC ins Cable 25 mm 2 As required
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Wire two unit of 13 A socket outlet in radial circuit
3 Wire four unit of 13 A socket outlet in ring circuit
4 Wire one unit DOL starter for air-conditioner point
5 Wire one unit of cooker control unit point
6 Wire one unit of water heater point
7 Test the functionality of each component by using multimeter or power supply whichever
applicable
8 Wire component according to circuit diagram
9 Test the functionality of completed project
Note
Ensure that the rating of protection device and size of wire
K prior to 31 March
2004 (BS 7671)
(formerly)
bare conductor
sleeved at terminations (formerly)
40 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 5 ndashWIRING SYSTEM OF 1 Oslash LIGHTING AND POWER CIRCUIT
POWER CIRCUITSa Radial circuits
Radial circuits are arranged in the same way as item 1 above in lighting layouts in that each socket
outlet is supplied via the previous one
Points to note
1 The number of socket outlets complying with BS 1363 is unlimited for a floor area of up to 50m 2 if
the circuit protection is a 30 A or 32 A cartridge fuse or circuit breaker the cable being 4 mm PVC
copper or 25 mm2 mineral insulated (mi)
2 The number of socket outlets is unlimited for a floor area up to 20 m 2 with any type of circuit
protection of 20 A using 25 mm2 PVC copper cable or 15 mm2 mi
3 The total number of fused spurs is unlimited
b ring final circuits
These circuits are the same as radial circuits except that the final socket outlet is wired back to the
supply position In effect any outlet is supplied from two directions (Fig 152)
Points to note
1 Every twin-socket outlet counts as two single-socket outlets
2 The number of non-fused spurs must not exceed the total number of points on the ring Fig 158
shows seven points on the ring and five spurs
3 The fuse rating of a fused spur box must not exceed 13 A and the current rating of all points supplied
by the fused spur must not exceed 13 A
4 Non-fused spurs must supply no more than one single or one double socket on the ring Fig 158
shows seven points on the ring and five spurs rating of all points supplied by the fused spur must not
exceed 13 A or one stationary appliance
CapacityMain conductor size
copper (mm2)
Earth conductor
size (mm2)
Circuit breaker
capacity (A)
Up to 600 W 15 15 6
600ndash1200 W 1525 15 10
1200ndash1800 W 254 25 16
41 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Ring circuit
(floor area 100 m2)25 15 3032
A2 radial circuit
(floor area 75 m2)40 25 3032
A3 radial circuit
(floor area 50 m2)25 15 20
Air conditioner (15 tonne) 60 60 3032
Cooker 60 60 3032
Water heater 40 40 20
Objectives
1 Identify component and the specification
2 Wire component according to the schematic diagram
3 Test the functionality of the circuit
42 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board Perforated 1
2 Cut out fuse and neutral link 60A 240V 1each
3 kWh meter 240V 40A 1
4 Switched Socket outlet 13A 240Vac 4
5 Single pole two way switch cw switch
box
5A 240Vac 2
6 RCCB ELCB 63 A Tripping current 100mA
415 Vac
1
7 3 pin plug 240Vac 13A 4
8 Single pole MCB 20 A 2
9 Single pole MCB 6A 1
10 Single pole MCB 20A 2
11 DOL starter 240Vac 2
12 1 phase induction motor 2hp 240 Vac 1
13 Self tapping Wood screw As required
14 DIN rail Stainless steel allum35 mm As required
15 PVC pipe 20mm dia As required
16 End box 20 mm dia 4
17 Flexible wires 05 mm 2 As required
18 Connectors 5 A As required
Procedures
43 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
4 Test the functionality of completed project
LESSON 6 ndash WIRING SYSTEM OF 3 Oslash DISTRIBUTION BOARD
Introduction
44 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
45 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
46 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
47 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
48 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify each component and the specification
2 Wire component according to the schematic diagram given
3 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting Board 450 x 600 mm Perforated metal 1
2 5 pin round socket and plug 415V ac 32A 1
3 Cut out fuse 60 A 3
4 Neutral link 1
5 kWatt hour meter 415V 60A 1
6 ELCB RCCB 3P+N In=63A415 Vac I trip= 300mA 1
7 ELCB RCCB 3P+N In=63A415 Vac I trip= 30mA 1
8 Single pole MCB 6A 240 V 3
9 Single pole MCB 20A 240 V 3
10 DOL starter 20 A 240Vac 2
11 Socket outlet 15 A 240 Vac 1
12 Switched Socket outlet 13 A 240 Vac 3
13 Led indicating light 5A 240 Vac 3
14 Single pole 4 gang 1 way switch 5A 240 Vac 2
15 Single pole 2 way switch 5A 240 Vac 2
16 1 phase induction motor 1 kW 240Vac 1
17 Metal trunking 30 mm x30 mm As required
18 Self tapping Wood screw 4 mm x 20 mm As required
19 DIN rail 25 mm x 1mm
20 GI steel rigid conduit 20mm As required
21 Flexible conduit 20mm As required
22 End box 20 mm 4
23 Flexible wires 05 mm 2 As required
24 Single core PVC insulated wire 15 mm 2 As required
25 Single core PVC insulated wires 25 mm 2 As required
26 Terminal block 10 A As required
Procedures
49 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify each components and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
4 Test the functionality of completed project
1 dead circuit test
2 life circuit
Note Proper earthing should be made
50 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 7 ndash WIRING SYSTEM OF THREE PHASE LIGHTING AND POWER CIRCUIT
51 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
52 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify component and the specification
2 Wire component according to the schematic diagram
3 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting bay Board Perforated metal 180 cm x 180 cm 1
2 k Watt hour meter 415V 60A 1
3 MCCB 415V 60A
4 ELCB RCCB In=60A415 Vac I trip=30mA 1
5 5 pin round Socket and
plug
415Vac 32A 4
6 Single pole MCB 6A 1
7 Triple pole MCB 20A 2
8 Triple pole Main switch 60A 1
9 DOL starter 240Vac 2
10 3 phase induction motor 2hp 415 Vac 1
11 1 phase induction motor 1
12 Metal trunking 30 mm x30 mm As required
13 Self tapping Wood screw 4 mm x 20 mm As required
14 DIN rail 25 mm x 1mm
15 GI steel rigid conduit 20mm As required
16 Flexible conduit 20mm As required
17 End box 20 mm 4
18 Flexible wires 05 mm As required
19 Connectors 10 A As required
Procedures
1 Identify each components and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
4 Test the functionality of completed project
1 dead circuit 2 life circuit test
5 Record the current drawn by the load as connected in star and delta
Note Proper earthing should be made
53 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 8 INSPECTION AND TESTING OF ELECTRICAL INSTALLATION
On completion of a wiring installation a number of tests on the installation have to be conducted to
ascertain that the wiring circuits and connected appliances are safe for use Prior to carrying out the
tests an inspection has to be done The results of the inspectionsupervision and test have to be
presented in Form G (as in Appendix IV) and Form H (as in Appendix V)
To have the test certification as in Form H the following tests shall be conducted
i Continuity Test
ii Insulation Resistance Test
iii Polarity Test
iv Earth Electrode Resistance test and
v Residual Current Device Test
1 Continuity Test
There are 3 main types of continuity tests for the final circuits-
i Protection Conductor Continuity Test
ii Final Ring Circuit Conductor Continuity Test
iii Live and Neutral Conductor Continuity Test
a) Protection Conductor Continuity Test
bull To ascertain that all protection conductors are connected in the correct and effective manner
bull Test equipment ndash Multimeter (Ohm range) or Ohm meter
54 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
bull Test Method
1 1048766 Ensure that the main switch RCD and MCB are open circuited (switched off) and all loads
are disconnected
2 1048766 Connected the test leads as in the Figure 81 The meter reading shall be less than 1 Ω
55 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Final Ring Circuit Conductor Continuity Test
bull To ensure that all conductors around the ring circuit have continuity
bull Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
bull Test Method
1 1048766 Disconnect both the supply source live conductors from the MCB the neutral conductor
from the neutral terminals and the earth conductor from the earth terminal in the distribution
fuse box
2 1048766 Connect the test leads as in the Figure 82 (EE)
3 1048766 Repeat the procedure for (L-L) and (N-N)
4 1048766 The meter reading value shall be less than 1 ohm
56 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Live and Neutral Conductor Continuity Test
a To ensure that each conductor in the circuit has continuity
b Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
2 Test Method
1 1048766 Switch off the Main switch RCD and MCB
2 1048766 Disconnect all loads
3 1048766 Switch on all switches in the circuit
4 1048766 Disconnect the fusesfinal circuit breakers and close the circuit
5 1048766 Carry out the test as shown in Figure 83
6 1048766 The meter reading value shall be less than 1Ω
57 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
58 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
CONTINUITY TEST
Insulation Resistance Test
i Ensure that there is no leakage current between phase conductors phase and neutral conductors and
phase conductor and earth
ii Test the strength of the cable insulation
iii Test Equipment ndash Insulation Resistance Tester operating voltage is 250VDC or 500VDC
iv Test Method
1 1048766 Switch off main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
59 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
4 1048766 Carry out test as in the Table below
5 1048766 Meter reading value shall be less than 1 Megaohm
60 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
61 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Insulation resitance test
62 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
INSULATION RESISTANCE TEST BETWEEN CONDUCTORS AND OPPOSITE POLARITY
Polarity Testi Ensure that each fuse or single pole control and protection device is connected only in the phase
conductor
ii Intermediate contact of Edison screw lamp holder is connected to the phase conductor
iii Ensure that phase neutral and earth conductors at socket outlets are connected at the correct
terminals
iv Test Equipment ndash Multimeter (Ohm range) or Ohm meter
v Test Method
1 1048766 Switch off Main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in Figure 85
63 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
5 1048766 Test switches and single phase control devices at the phase conductors
6 1048766 Test socket outlet connection sources
7 1048766 Test Edison screw lamp holder connections
8 1048766 Meter reading value shall be less than 1 Ω
64 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Polarity test
65 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Earth Electrode Resistance Testi To test the earth electrode resistance
ii To ascertain the suitability of the location of the electrode
iii To ensure that the electrode is not buried within the resistance area of another electrode
iv Test equipment ndash Earth Resistance Tester
v Test method -
1 1048766 Terminal rsquoErsquo is connected to the electrode to be tested (green conductor)
2 1048766 Terminal lsquoPrsquo is connected to the potential spike (yellow conductor) at a distance of 10
meters from the earth electrode
3 1048766 Terminal lsquoCrsquo is connected to the current spike (red conductor) at a distance of 20 meters
from the earth electrode
Earth Electrode Resistance Measurement Method (Figure 86)
This test must be repeated at least three times to ensure that the reading is not affected by interacting
earthing regions
i Record the first reading (Z1) Example Z1 = 10 Ω
ii Move the voltage spike to a distance of 6 meters from the original position Record the second
reading (Z2 ) Example Z2 = 10 Ω
iii Move the voltage spike to a distance of 6 meters from the original position Record the third
reading (Z3) Example Z3 = 10 Ω
66 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Residual Current Device Testi Ensure that the residual current device (RCD) trips within the set time on the occurrence of current
leakage to earth
ii Test Equipment ndash RCD Tester RCCB Tester
iii Test Method 1
1 1048766 Use the Trip Test Button
2 1048766 Press the trip button found on the RCD to determine if it trips or otherwise This test would
not be able to determine the sensitivity of the RCD nor the time taken for it to trip
iv Test Method 2
i 1048766 Use a RCD Tester
ii This equipment is equipped with a 13A plug which can be connected to a 13A socket outlet
Select the RCD sensitivity to be the same as the sensitivity of the RCD to be tested to
determine if the RCD can trip The time to trip shall not exceed 40 mS
iii 1048766 Test method ndash
a) Position the selection switch in accordance with the sensitivity of the RCD used
Example 100 mA 01 A
b) Position the operations switch to lsquoNo Triprsquo (frac12 Rated mA = 50) connect the 3 pin plug to
the 13A socket outlet
67 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
c) Switch on the 13A socket outlet ndash ensure that the P-N and P-E lights light up
This shows that the polarity is correct (Note if both the lights as above do not light up the test cannot
be continued)
d) Press the test button ndash the reading shows less than 200 mS and simultaneously the lsquotestrsquo light lights
up and the P-N and P-E lights do not light up At that instant the RCD will not trip
e) Move the selection switch to 180o (+ve wave) ndash repeat steps (d) and (e) Move the operations
switch to lsquoTriprsquo (Rated mA = 100)
g) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200mS
h) Move the selection switch to 0o (-ve wave)
i) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
j) The above test is repeated until a near correct reading is obtained
k) Record the test results
l) Change the operations switch to lsquoFast Triprsquo and press the test button ndash RCD will trip within a
time not exceeding 40 millisecond
m) Repeat a number of times at 0o or 180o
On completion of a wiring installation a number of tests on the installation have to be conducted to
ascertain that the wiring circuits and connected appliances are safe for use Prior to carrying out the
tests an inspection has to be done the following tests shall be conducted
i Continuity Test
ii Insulation Resistance Test
iii Polarity Test
iv Earth Electrode Resistance test and
v Residual Current Device Test
821 Continuity Test
There are 3 main types of continuity tests for the final circuits-
i Protection Conductor Continuity Test
ii Final Ring Circuit Conductor Continuity Test
68 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
iii Live and Neutral Conductor Continuity Test
a) Protection Conductor Continuity Test
bull To ascertain that all protection conductors are connected in the correct and effective manner
bull Test equipment ndash Multimeter (Ohm range) or Ohm meter
bull Test Method
1 1048766 Ensure that the main switch RCD and MCB are open circuited (switched off) and all loads are
disconnected
2 1048766 Connected the test leads as in the Figure 81
3 1048766 The meter reading shall be less than 1 Ω
Final Ring Circuit Conductor Continuity Test
bull To ensure that all conductors around the ring circuit have continuity
bull Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
bull Test Method
1 1048766 Disconnect both the supply source live conductors from the MCB the neutral conductor
from the neutral terminals and the earth conductor from the earth terminal in the distribution
fuse box
2 1048766 Connect the test leads as in the Figure 82 (EE)
3 1048766 Repeat the procedure for (L-L) and (N-N)
4 1048766 The meter reading value shall be less than 1 ohm Figure 82 - Final Ring Circuit Conductor
Continuity Test Ohm Meter
Disconnect both the supply source cables from mcbfuse
Take readings at earth conductors of both sources and note resistance readings
Live and Neutral Conductor Continuity Test
1 To ensure that each conductor in the circuit has continuity
2 Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
3 Test Method
1 1048766 Switch off the Main switch RCD and MCB
2 1048766 Disconnect all loads
3 1048766 Switch on all switches in the circuit
4 1048766 Disconnect the fusesfinal circuit breakers and close the circuit
5 1048766 Carry out the test as shown in Figure 83
6 1048766 The meter reading value shall be less than 1 ohm Figure 83 - Live and Neutral
Conductor Continuity Test Ohm Meter
Insulation Resistance Test
69 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
i Ensure that there is no leakage current between phase conductors phase and neutral conductors and
phase conductor and earth
ii Test the strength of the cable insulation
iii Test Equipment ndash Insulation Resistance Tester Operating voltage is 250VDC or 500VDC
iv Test Method
1 1048766 Switch off main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in the Table below
5 1048766 Meter reading value shall be less than 1 Megaohm
Polarity Test
i Ensure that each fuse or single pole control and protection device is connected only in the phase
conductor
ii Intermediate contact of Edison screw lamp holder is connected to the phase conductor
iii Ensure that phase neutral and earth conductors at socket outlets are connected at the correct
terminals
iv Test Equipment ndash Multimeter (Ohm range) or Ohm meter
v Test Method
1 1048766 Switch off Main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in Figure 85
5 1048766 Test switches and single phase control devices at the phase conductors
6 1048766 Test socket outlet connection sources
7 1048766 Test Edison screw lamp holder connections
8 1048766 Meter reading value shall be less than 1 Ω
Earth Electrode Resistance Test
i To test the earth electrode resistance
70 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
ii To ascertain the suitability of the location of the electrode
iii To ensure that the electrode is not buried within the resistance area of another electrode
iv Test equipment ndash Earth Resistance Tester
v Test method -
1 1048766 Terminal rsquoErsquo is connected to the electrode to be tested (green conductor)
2 1048766 Terminal lsquoPrsquo is connected to the potential spike (yellow conductor) at a distance of 10
meters from the earth electrode
3 1048766 Terminal lsquoCrsquo is connected to the current spike (red conductor) at a distance of 20 meters
from the earth electrode E P C Electrode 10 meter 10 meter
Figure 86 ndash Earth Electrode Resistance Measurement Test Equipment
Earth Electrode Resistance Measurement Method (Figure 86)
This test must be repeated at least three times to ensure that the reading is not affected by interacting
earthing regions
i Record the first reading (Z1) Example Z1 = 10 Ω
ii Move the voltage spike to a distance of 6 meters from the original position Record the second
reading (Z2) Example Z2 = 10 Ω
iii Move the voltage spike to a distance of 6 meters from the original position Record the third
reading (Z3)
Example Z3 = 10 Ω
Residual Current Device Test
71 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
i Ensure that the residual current device (RCD) trips within the set time on the occurrence of current
leakage to earth
ii Test Equipment ndash RCD Tester RCCB Tester
iii Test Method 1
1 1048766 Use the Trip Test Button
2 1048766 Press the trip button found on the RCD to determine if it trips or otherwise This test would
not be able to determine the sensitivity of the RCD nor the time taken for it to trip
iv Test Method 2
1048766 Use a RCD Tester
This equipment is equipped with a 13A plug which can be connected to a 13A socket outlet Select the
RCD sensitivity to be the same as the sensitivity of the RCD to be tested to determine if the RCD can
trip The time to trip shall not exceed 40 mS
1048766 Test method ndash
a) Position the selection switch in accordance with the sensitivity of the RCD used
Example 100 mA 01 A
b) Position the operations switch to lsquoNo Triprsquo (frac12 Rated mA = 50) connect the 3 pin plug to
the 13A socket outlet
c) Switch on the 13A socket outlet ndash ensure that the P-N and P-E lights light up This shows that
the polarity is correct (Note if both the lights as above do not light up the test cannot be
continued)
d) Press the test button ndash the reading shows less than 200 millisecond and simultaneously the
lsquotestrsquo light lights up and the P-N and P-E lights do not light up At that instant the RCD will
not trip
e) Move the selection switch to 180o (+ve wave) ndash repeat steps (d) and (e) = 100)
f) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
g) Move the selection switch to 0o (-ve wave)
h) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
i) The above test is repeated until a near correct reading is obtained
j) Record the test results
k) Change the operations switch to lsquoFast Triprsquo and press the test button ndash RCD will trip within a
time not exceeding 40 mS
l) Repeat a number of times at 0o or 180o
72 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 9 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (DC)
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
73 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Start stop button 240Vac 5A 2
9 Filament lamp (Bulb ) 240Vac 40W 3
10 Overload Relay 415V 20A 3
11 Three phase induction motor 5 hp 3
12 Single phase step down transformer 2500VA 1
13 Single core PVC insulated Cable 1mm 2 As required
14 Single core PVC insulated Cable 25mm 2 As required
15 DIN rail 35 mm As required
16 PVC type Cable tray 50 mm x 50 mm As required
17 Cable ties 4 ldquo As required
18 Flexible wires 05 mm As required
19 PVC Connectors 5 A amp 20 A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the schematic
diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a optional exercise
i Simple DOL starter
ii Forward reverse DOL starter
iii Forward Reverse Dahlander motor
iv Three motors operated in sequence by DOL starter operated by manual push
button or time delay relay
74 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
a One loop per-cycle
b Continuous operation in a loop
c optional circuit design to represent the same task
v Only one out of three motors to be operated at a time (quiz)
4 Test the functionality of completed project
LESSON 10 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (AC)
75 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 1
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Lamp point 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
76 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
11 Overload Relay 415V 20A 3
12 Three phase induction
motor
5 hp 3
13 Single core PVC insulated
Cable
1mm 2 As required
14 Single core PVC insulated
Cable
25mm 2 As required
15 DIN rail 35 mm As required
16 PVC type Cable tray 50 mm x 50 mm As required
17 Cable ties 4 ldquo As required
18 Flexible wires 05 mm As required
19 PVC Connectors 5 A amp 20 A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the
schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram optional exercise
4 Simple DOL starter
5 Forward reverse DOL starter
6 Test the functionality of completed project
77 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 1
78 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
cm
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Indicating light 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
11 Overload Relay 415V 20A 3
12 Three phase induction motor 5 hp 3
13 Single phase step down
transformer
2500VA 1
14 Single core PVC insulated
Cable
1mm 2 As required
15 Single core PVC insulated
Cable
25mm 2 As required
16 DIN rail 35 mm As required
17 PVC type Cable tray 50 mm x 50 mm As required
18 Cable ties 4 ldquo As required
19 Flexible wires 05 mm As required
20 PVC Connectors 5 A amp 20 A 240 V As required
21 Single pole MCB 6A 240 V 1
22 Single pole MCB 2A 240 V 1
23 Triple pole MCB 20A 415 V 1
24 Mounting board 30 cm x 40 cm x 3
cm
1
25 Relay cw 11 pin socket 10 A 240 Vac 2
26 Time delay relay 10 A 240 Vac 3
27 Triple pole Contactor 20A 240Vac 3
28 Batten type Lamp holder 240Vac 10 A 3
29 Start stop button 240Vac 10A 2
30 Indicating light (Bulb ) 240Vac 25W 3
31 Overload Relay 415V 20A 1
32 Three phase dahlander type
induction motor
5 hp 1
33 Single phase step down
transformer
24024Vac
2500VA
1
79 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
34 Single core PVC insulated
Cable
1mm 2 As required
35 Single core PVC insulated
Cable
25mm 2 As required
36 DIN rail 35 mm As required
37 PVC type Cable tray 50 mm x 50 mm As required
38 Cable ties 4 ldquo As required
39 Flexible wires 075 mm As required
40 PVC Connectors 5 A amp 20 A 240 V As required
41 Terminal block 20A 240Vac As required
Procedures
5 Identify each component according to specification and quantity required from the schematic
diagram attached
6 Test the functionality of each component by using multi-meter or power supply whichever
applicable
7 Wire component according to circuit diagram
8 Three motors operated in sequence by DOL starter operated by manual push button or time
delay relay
a One loop per-cycle
b Continuous operation in a loop
c optional circuit design to represent the same task
d Only one out of three motors to be operated at a time (quiz)
9 Test the functionality of completed project
80 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
BASIC DESIGN INDUSTRIAL MOTOR CONTROL (SEQUENCE CONTROL)
THREE PHASE INDUCTION MOTOR OPERATED IN SEQUENCE BY DIRECT ON LINE
STARTER
LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
81 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
82 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Lcd lamp indicator 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
11 Overload Relay 415V 20A 3
12 Three phase induction motor 5 hp 3
13 Single phase step down transformer 2500VA 1
14 Single core PVC insulated Cable 1mm 2 As required
15 Single core PVC insulated Cable 25mm 2 As required
16 DIN rail 35 mm As required
17 PVC type Cable tray 50 mm x 50 mm As required
18 Cable ties 4 ldquo As required
19 Flexible wires 1 mm Oslash As required
20 PVC Terminal block 10A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the schematic
diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a optional exercise
i Forward Reverse dahlander motor
4 Test the functionality of completed project
83 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
THREE PHASE DAHLANDER TYPE INDUCTION MOTOR OPERATED FORWARD AND
REVERSE OPERATION BY DIRECT ON LINE STARTER
84 ndash 99EASYTECH ENTERPRISE
LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
Introduction
If a motors windings are connected in the star configuration any two phases will be in series across
the supply and hence the line current will be smaller(by 577) than if the windings were connected in
the delta arrangement
Hence larger-type motors with heavy starting currents are first connected in star and then when the
starting currents fall in delta This of course means that all six of the ends of the windings must be
brought to terminations outside the casing (Fig 833)
EZTECH
EZTECH ELECTRICAL INSTALLATION GUIDE
The automatic version of this starter incorporates a timing relay which automatically changes the
connections from star to delta Figs 834 and 835 show the wiring and schematic diagrams for a star
delta starter
Objectives
1 Identify component and the specification
2 Design forward reverse star delta starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
2 ndash 99EASYTECH ENTERPRISE
REV -C
LEGENDMCCB Moulded Case Circuit BreakerTOR Thermal Over Load RelayFOW-C Mains Forward ContactorREV-C Mains Reverse ContactorDC Delta ContactorSC Star ContactorS-SW Mains Selector Switch
SC
V2
W2
U2
DC
V1
W1
U1
TOR
TOR
FOW-C
30A MCCB
TOR
MAIN CIRCUIT FORWARD REVERSE STAR DELTA
RYBN S
-SW
3 PHASEINDUCTION MOTOR
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Relay 10 A 240V 3
5 Triple pole Contactor
6 cw NO NC auxiliary contact
240Vac 20 A 4
7 Overload Relay 415 V 1
8 LED indicator 240vac 5 A 4
9 Start stop button 240Vac 5A 2
10 DIN rail 35 mm As required
11 Flexible wires 1 mm As required
12 Single core PVC insulated
wire
25 mm As required
13 Terminal block 20 A As required
14 Squirrel cage motor 5kW 1
15 5 pin plug and socket 415V 20A 1
16 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
3 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
a Manual star delta
b Manual Forward reverse star delta starter
c Automatic star delta starter
d Automatic Forward reverse star delta starter
4 Test the functionality of completed project
4 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
Objectives
1 Identify component and the specification
2 Design auto transformer starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
5 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Autotransformer starter is used to start a 3 phase induction motor that has a rating between 10 to 15 hp
6 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Autotransformer set 10Kw 415 V 50 Hz 1
5 Triple pole Contactor 240Vac 4
6 Batten type Lamp holder 240 Vac 105 A 4
7 Start stop button 240Vac 10A 4
8 Filament lamp (Bulb ) 240Vac 40W 4
9 DIN rail 35 mm As required
10 Flexible wires 1 mm As required
7 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
11 Single core PVC insulated
wire
25 mm As required
12 Terminal block 20 A As required
13 Squirrel cage motor 10kW 1
14 5 pin plug and socket 415V 20A 1
15 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a open transient autotransformer starter
b close transient autotransformer starter
c Forward reverse autotransformer starter
4 Test the functionality of completed project
8 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
Objectives
1 Identify component and the specification
2 Design rotor resistance starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
9 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Rotor Resistor set 10kW 1
5 Triple pole Contactor 240Vac 20A 4
6 Indicating light 240vac 5 A 4
7 Start stop push button 240Vac 5A 4
8 DIN rail 35 mm As required
9 Flexible wires 1 mm 2 As required
10 Single core PVC insulated wire 25 mm 2 As required
11 Terminal block 20 A As required
12 Slip Ring motor 10kW 1
13 5 pin round 3 phase socket 415V 20A 1
14 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
10 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
4 Test the functionality of completed project
a Dead circuit test b Life circuit test
5 Measure starting and running Amps
LESSON 16
TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
An installation in general will suffer damage
Damage usually occurs on the electric motor control as follows
1 Damage to the main circuit
2 Damage to the control circuit
The cause of the damage
i Overcurrent overload short circuit
ii Leakage current to ground
iii Equipment malfunction
iv The main control circuit
a Trip of main circuit protection devices fire
b Defect of motor terminal such as short circuit fire loose
v The control circuit is not functioning -
a contactor relay relay time overload relay does not work damaged burned
b Loose cable connection disconnected
Detecting and Repairing Damage
Examples of damage are as follows
i Motor does not work
ii Motor function and overload relay trips
iii Motor function but only partially functional control circuit
Methods of detecting damage
Among the known methods necessary to detect damage are as follows
1 Turn off the electricity at the main switch (main switch) in order to avoid any danger during the
work carried out to detect damage
2 Check all the protective gear that controls the motor control main circuit
11 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
3 Make sure the damage function control circuit
4 Check the control circuit according to the schematic circuit diagram of the motor control
5 Check the operation of the control circuit
Note
Use wiring that has been installed on the SYSTEM OF MOTOR CONTROL BOARD by Forward
Reverse control circuit for Star Delta to test and look for damage
SELF-ASSESSMENT QUESTIONS
1 (a) Explain what is meant by the term lsquoback emfrsquo in a motor
(b) Outline the basic differences between series shunt and compound wound dc motors
2 (a) With the aid of diagrams explain how the speed of series shunt and compound-wound motors
may be controlled
(b) A 440V dc shunt-wound motor has a field resistance of 200R and an armature resistance of 06 R
When its speed is 20 rev d second the current drawn from the supply is 122A Calculate its back
emf at this speed If the speed were decreased to 19 revssecond the field flux remaining unchanged
calculate the new back emf and the new armature current
3 A load of 64 kW at 240 V is supplied from the terminals of a shunt-wound dc generator The field
resistance is 180 A Calculate the armature current
4 (a) Explain with the aid of a diagram how a rotating magnetic field may be
(b) What is meant by lsquosynchronous speedrsquo
Calculate the synchronous obtained speed of a 12 pole motor if the supply frequency is 50Hz
5 (a) Explain the action of a synchronous motor
(b) What methods are available to start a synchronous motor Explain with diagrams
6 (a) Explain the action of a cage induction motor
(b) What is meant by the term lsquosliprsquo
Calculate the percentage slip of a six pole induction motor running at 162 revssecond from a 50 Hz
supply
7 Describe with sketches three different ways of starting a single-phase induction motor
12 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
8 Explain with the aid of a sketch the action of a three-phase DOL starter
What are dashpots used for How are remote start and stop buttons connected
9 A I0 kW 240V 50Hz single-phase cage rotor induction motor is 85efficient and has a PF of 068
lagging Calculate the motor current and the value of capacitor required to raise the PF to 093
lagging
10 Calculate the torque developed by an 18 kW four-pole induction motor run at 35 slip from a
50Hz supply
APPENDIX 1
13 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 11
14 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 111
Attachment Reference
httpswwwtlc-directcoukBook621htm
httpwwwstgovmyindexphpms
15 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Flexible Cables
i Flexible cables of cross sectional area less than 40 mm2 are used in installations for electrical
accessories such as ceiling roses lamp fixtures or attachments socket plugs for mobile
appliances etc
ii Flexible cables shall not be used for permanent wiring
iii Flexible cables for the permanent use of electrical appliances should not exceed 3 meters in
length
37 Functions and Colour Identification of Flexible Cables
Conductor Insulation and Types of WiringVarious material and insulation layers are used for conductor protection Cable selection in
accordance to insulation layers must be done correctly for the type of the wiring installation as
shown in the table below
Functions and Colour Identification of Non Flexible CablesThe following table shows the functions and colour identification of non flexible cables
3 SELECTION OF WIRING ACCESSORIES
i All wiring accessories to be used have to be of those approved by the Energy Commission and
labeled with labels issued by SIRIM For all wiring using UPVC conduits -
13 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
a) Switches socket outlets 3 pin plugs ceiling roses connectors sockets ndash construction material shall
be of polycarbonate type
iii For all wiring using metal conduits - Switches socket outlets and connectors ndash construction
material shall be of metal clad type and All accessories shall be effectively earthed
iv Switch fuse used in single phase installations shall have the fuse permanently connected and not
move with the fuse
v Fuse switch used in 3 phase domestic installations also has fuse and switch The fuse connector is
installed together to allow the fuse to move simultaneously with the switch
vi Lamp
a) Fluorescent lamps using magnetic ballasts (watt loss not exceeding 6 watts) shall be
equipped with dry paper type capacitor
b) Fluorescent lamps using electronic ballasts or high frequency electronic ballasts do not
need capacitors
c) Outdoor domestic lamp installations shall use weather proof and water proof lamps
d) Submerged light installations (example in swimming pools fountains etc) shall have water
proof lamps with a voltage not exceeding 12 Volt AC
vii Electric water heaters is divided into 2 types namely
1 instantaneous water heaters and
2 stored water heaters (storage tank type)
a) Instantaneous water heaters shall be equipped with a 2 pole control switch and its own
residual current device
b) Storage water heaters (storage tank type) shall be installed with an
Water heaters exceeding 3kW shall be permanently connected to a 20A30A rated circuit
breakerfuse with an isolator switch and residual current device
viii Electric cookers exceeding 3kW shall have its own circuit connected permanently to a 30A rated
circuit breaker or fuse with an isolator switch and cooker control unit incorporated with a 13A socket
outlet Two or more cooker appliances may be installed in the same room within a distance of 2
meters
ix Electric motors (fence gate air conditioners fountains swimming pools fish ponds water
pumps) exceeding 373W but not exceeding 2238W shall be connected permanently to a 20A30A
rated circuit breakerfuse together with an isolator motor starter and 15A socket outlet
14 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
The motor starter shall be of Direct-On-Line type with the appliance together with the contactor
overload relay and on-off control The circuit breakerfuse which controls the motor circuit shall be
capable of withstanding the starting current of the motor
x Electric bells ndash the circuit shall have a push button switch and a ACDC transformer
xi Ceiling fans shall conform to clause 21101 of the MS 12192002 standard with regards to test on
the suspension system of ceiling fans
EARTHING OF ELECTRICAL INSTALLATIONS51 Earthing
Earthing is a connection system between the metallic parts of an electrical wiring system and the
general mass of the earth This will provide an easy path with a low impedence or resistance to earth to
enable the protection system to operate effectively It will thus ensure safety to human
beingsconsumers from the dangers of electric shocks if earth leakage currents are present In general
an electrical installation is earthed because of -
i Safety reasons
ii Protection system requirements
iii Need to limit over voltages
iv Need to provide a path for electrical discharge
v Legal requirements
52 Classification of Earthing
Generally earthing can be divided into 2 parts namely -
i System Earthing
a To isolate the system under fault conditions
b To limit the potential difference between conductors which are not insulated in an area
c To limit the occurrence of over voltages under various conditions
ii Equipment Earthing
Equipment earthing is undertaken to protect human beingsconsumers If a live source comes into
contact with the equipment body electrical energy will flow to the earth without flowing through the
human being consumerrsquos body This is because of the fact that the human body has a greater
resistance compared with the resistance to earth
53 Types and Functions of Earthing Accessories
Earthing accessories are as follows -
i Earthing Electrode
Copper jacketed steel core rods are used as electrodes for domestic wiring
ii Equipotential Bonding
15 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
This is the conductor which is connected between the consumer earthing point and the exposed
metallic part The minimum cable size for this purpose is 10 mm2
iii Protection Conductor
This is the conductor which connects the consumer earthing point with other parts of the installation
which needs earthing Its size is as follows-
a) Same size as the phase cable up to a size of 16mm2
b) 16 mm2 if the phase cable size is between 16 mm2 and 35 mm2
c) Half the size of the phase cable if the size of the phase cable exceeds 35 mm2
54 Earthing Arrangements Using a TT System
i The first alphabet indicates the earthing arrangements from the supply side
ii The second alphabet indicates the earthing arrangement in the consumerrsquos installation
T ndash first Indicates that the supply system has its own earthing arrangements
T ndash second Indicates that all metallic frames of the electrical appliances etc are connected directly to
earth
Parts that are Required to be Earthed
i All metallic structures in the wiring system (non current carrying) such as metallic covers conduits
ducts the armour of catenary wires etc
ii A secondary winding point in a transformer and
iii Frame of metal roof truss
56 Parts that are not Required to be Earthed
i Short isolated metallic parts for mechanical protection of cables which have non metallic sheaths
other than conduits which are connected at entry points between the building and conduits which
protect discharge lamp cables
ii Cable clips for installing cables
iii Metallic covers for lamps
16 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
iv Small metallic parts such as screws and name plates which are isolated by means of insulation
v Metallic lamp parts for filament lamps in water proof floors
57 Termination to Earth
The termination to earth is done as shown in Figure 72
Earth Electrode Resistance
The maximum permitted earth electrode resistance for different types of installations is as shown in
the Table below
Earth electrode for installations protected by RCDs of sensitivity 100mA 10 Ω
Lightning arrestor earth electrode 10 Ω
Legal Requirements
i Sub regulation 12(1) and 12(2) of the Electricity Regulations 1994 state that any electrical wiring in
an installation shall be under the immediate supervision of a Wireman with Single Phase Restriction or
Three Phase Restriction Upon completion the Wireman shall certify a Supervision and Completion
Certificate
ii Sub regulation 13(1) and 13 (2) of the Electricity Regulations 1994 state that the installation shall
be tested by a Wireman with Single Phase Restriction or a Wireman with Three Phase Restriction
authorized to test any installation and who shall certify a Test Certificate for the installation
iii Sub regulation 14(1) of the Electricity Regulations 1994 states that the Supervision and
Completion Certificate and the Test Certificate as in regulations 12 and 13 shall be in Forms G and H
respectively as prescribed in the First Schedule
17 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
4 SAFETY REQUIREMENTS FOR ELECTRICAL WIRING WORKS IN RESIDENTIAL BUILDINGS
61 Safety Requirements
Safety requirements for electrical wiring works have to be followed to eliminate any accidents which
can result in physical damage or loss of life or property Failure to meet the safety regulations may
result in workers consumers or the public being inflicted with electrical shocks
In addition to this safety steps will also encourage workers or electricity consumers who are
disciplined and who always give importance to safety
62 Safety Steps
Safety requirements have to be followed whenever electrical works are undertaken in a residential
building
i Personal Safety
a Use suitable personal protection equipment as needed such as safety shoes gloves safety helmet
etc when at the work place
b Use safety clothing suitable for the work to be undertaken
c Do not wear jewellery or decorative items such as rings watches chains etc while carrying out
electrical works
ii Safety at the Work Place
a Acquire knowledge about the dangers of electrical works that is to be undertaken and how to deal
with those dangers
b Always adhere to the safety regulations which have been set for the work place
c Ensure that the electricity supply is switched off before carrying out the works
d Acquire the needed knowledge and practice a cautious and calm attitude while working ensure
cleanliness in and around fellow workers
e While working at elevated places the worker should always use suitable equipment such as wooden
or aluminium ladders iron scaffoldings or platforms safety belts or other equipment needed to ensure
that the work can be undertaken safely
f Use electrical equipment which is operational and safe to be used and ensure that the supply for it is
being supplied through a residual current device (RCD) with a sensitivity of 30 mA
g Ensure that exposed temporary supply electrical cables have mechanical protection
h If inflammable or corrosive material is present necessary safety steps have to be undertaken as
required by the relevant safety regulations
63 Dangers of Electrical Shocks
i Electrical Shock
Electrical shocks can occur due to direct or indirect contact
a Direct Contact
18 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Direct contact occurs when the worker or consumer receives an electrical shock on touching directly a
live conductor or cable
b Indirect Contact
Here the electric shock occurs due to contact with a part which is connected to the electrical
installation and not to a direct contact with a live cable or conductor possibly due to damages in the
appliance or insulation resulting in leakages of current
Why Electric Shocks Occura Unsafe Work Method or Action Undertaking Electrical Work Without Disconnecting the
Supply
Maintenance or circuit testing work done without disconnecting the supply will have a high possibility
of electrical shocks occurring
bull Not Following Safe Work Procedures
To eliminate the occurrence of electrical shocks each worker has to always follow safe work
procedures which are set by regulations and standards
b Defects in the Electrical System
i Leakage Current
Leakage currents or earth leakage currents can result in the metallic frames becoming live and
energised This can give rise to the danger of electrical shock to the worker consumer or the public if
they hold or come into contact with the metallic frame
ii Exposed Conductor or Disconnected Cable
Exposed conductors or cables which are broken and are alive (energised) can result in electrical shock
when touched The supply source must be immediately isolated or switched off and a report must be
made to the responsible entity
64 First Aid and Basic Pulmonary Resuscitation
i First Aid
First aid is the initial assistance given to a person who has met with an accident is sick or is injured to
prevent the condition of the victim from becoming more serious while awaiting the arrival of the
paramedics (ambulance) or before being brought to the hospital
i Pulmonary Resuscitation
Pulmonary resuscitation has to be undertaken to assist the victim who has breathing difficulties as a
result of being drowned receiving an electrical shock etc Pulmonary resuscitation has to be carried
out in accordance to the correct method as stated in the first aid manuals issued by accredited first aid
bodies
ii First Aid Box
19 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
A first aid box has to be provided by the building owner construction site supervisor or brought
personally by the worker under the supervision of the responsible person
65 Training Programme
The management shall conduct periodic training programmes for the workers with regards to work
safety on aspects including the following -
i Dangers of electrical work being undertaken and how to control those dangers
ii The safety regulations set for the work place and
iii First aid procedures
66 Fire Prevention
Fire Extinguisher A suitable functioning fire extinguisher to control fires has to be made available at
the work place at all times
67 Competent Person
The Electricity Regulations 1994 require that all electrical work has to be undertaken by or under the
direct supervision of a competent person registered with the Energy Commission Besides that the
electrical contractor undertaking the electrical work has also to be registered with the Energy
Commission The installation owner thus has to ensure that the appointed electrical contractor is
registered with the Energy Commission and that the registration is still valid
INSTALLATION CIRCUITS AND SYSTEMS1 Block diagrams
These show using squares rectangles etc the sequence of a system without too much technical detail
eg Figures 1517 and 1526
2 Layout diagrams
These are very similar to block diagrams but they indicate more technical detail and tend to show
items in their correct geographical location (eg Figures 1518 and 1519)
3 Circuitschematic
These show how a circuit functions and takes no account of exact locations of terminals or equipment
(eg Figures 1528 1529 1532 1534 etc)
4 Wiring diagram
These indicate how a circuit or system is physically wired (eg Figures 152 154 156 etc)
Most induction motors are started directly on line but when very large motors are started that way
they cause a disturbance of voltage on the supply lines due to large starting current surges To limit the
starting current surge large induction motors are started at reduced voltage and then have full supply
voltage reconnected when they run up to near rotated speed Two methods are used for reduction of
starting voltage are star delta starting and auto transformer stating
20 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Working Principal of Star-Delta Starter
This is the reduced voltage starting method Voltage reduction during star-delta starting is achieved by
physically reconfiguring the motor windings as illustrated in the figure below During starting the
motor windings are connected in star configuration and this reduces the voltage across each winding 3
This also reduces the torque by a factor of three After a period of time the winding are reconfigured as
delta and the motor runs normally
StarDelta starters are probably the most common reduced voltage starters They are used in
an attempt to reduce the start current applied to the motor during start as a means of reducing the
disturbances and interference on the electrical supply
Traditionally in many supply regions there has been a requirement to fit a reduced voltage
starter on all motors greater than 5HP (4KW) The StarDelta (or WyeDelta) starter is one of the
lowest cost electromechanical reduced voltage starters that can be applied
The StarDelta starter is manufactured from three contactors a timer and a thermal overload
The contactors are smaller than the single contactor used in a Direct on Line starter as they are
controlling winding currents only The currents through the winding are 1root 3 (58) of the
current in the line
There are two contactors that are close during run often referred to as the main contractor and
the delta contactor These are AC3 rated at 58 of the current rating of the motor The third
contactor is the star contactor and that only carries star current while the motor is connected in star
The current in star is one third of the current in delta so this contactor can be AC3 rated at one
third (33) of the motor rating
Star-delta Starter Consists following units
1) Contactors (Main star and delta contactors) 3 Norsquos (For Open State Starter) or 4 Norsquos (Close
Transient Starter)
2) Time relay (pull-in delayed) 1 No
3) Three-pole thermal over current release 1No
4) Fuse elements or automatic cut-outs for the main circuit 3 Nos
5) Fuse element or automatic cut-out for the control circuit 1No
Power Circuit of Star Delta Starter
1 The main circuit breaker serves as the main power supply switch that supplies electricity to the
power circuit
2 The main contactor connects the reference source voltage R Y B to the primary terminal of the
motor U1 V1 W1
21 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
3 In operation the Main Contactor (KM3) and the Star Contactor (KM1) are closed initially and
then after a period of time the star contactor is opened and then the delta contactor (KM2) is
closed The control of the contactors is by the timer (K1T) built into the starter The Star and Delta
are electrically interlocked and preferably mechanically interlocked as well In effect there are
four states
4 The star contactor serves to initially short the secondary terminal of the motor U2 V2 W2 for the
start sequence during the initial run of the motor from standstill This provides one third of DOL
current to the motor thus reducing the high inrush current inherent with large capacity motors at
startup
5 Controlling the interchanging star connection and delta connection of an AC induction motor is
achieved by means of a star delta or wye delta control circuit The control circuit consists of push
button switches auxiliary contacts and a timer
Control Circuit of Star-Delta Starter (Open Transition)
1 The ON push button starts the circuit by initially energizing Star Contactor Coil (KM1) of star
circuit and Timer Coil (KT) circuit
2 When Star Contactor Coil (KM1) energized Star Main and Auxiliary contactor change its
position from NO to NC
3 When Star Auxiliary Contactor (1)( which is placed on Main Contactor coil circuit )became
NO to NC itrsquos complete The Circuit of Main contactor Coil (KM3) so Main Contactor Coil
energized and Main Contactorrsquos Main and Auxiliary Contactor Change its Position from NO
To NC This sequence happens in a friction of time
4 After pushing the ON push button switch the auxiliary contact of the main contactor coil (2)
which is connected in parallel across the ON push button will become NO to NC thereby
providing a latch to hold the main contactor coil activated which eventually maintains the
control circuit active even after releasing the ON push button switch
5 When Star Main Contactor (KM1) close its connect Motor connects on STAR and itrsquos
connected in STAR until Time Delay Auxiliary contact KT (3) become NC to NO
6 Once the time delay is reached its specified Time the timerrsquos auxiliary contacts (KT)(3) in
Star Coil circuit will change its position from NC to NO and at the Same Time Auxiliary
contactor (KT) in Delta Coil Circuit(4) change its Position from NO To NC so Delta coil
energized and Delta Main Contactor becomes NO To NC Now Motor terminal connection
change from star to delta connection
7 A normally close auxiliary contact from both star and delta contactors (5amp6)are also placed
opposite of both star and delta contactor coils these interlock contacts serves as safety
switches to prevent simultaneous activation of both star and delta contactor coils so that one
22 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
cannot be activated without the other deactivated first Thus the delta contactor coil cannot be
active when the star contactor coil is active and similarly the star contactor coil cannot also
be active while the delta contactor coil is active
8 The control circuit above also provides two interrupting contacts to shutdown the motor
The OFF push button switch break the control circuit and the motor when necessary The
thermal overload contact is a protective device which automatically opens the STOP Control
circuit in case when motor overload current is detected by the thermal overload relay this is to
prevent burning of the motor in case of excessive load beyond the rated capacity of the motor
is detected by the thermal overload relay
9 At some point during starting it is necessary to change from a star connected winding to a
delta connected winding Power and control circuits can be arranged to this in one of two
ways ndash open transition or closed transition
What is Open or Closed Transition Starting
(1) Open Transition Starters
Discuss mention above is called open transition switching because there is an open state between
the star state and the delta state
In open transition the power is disconnected from the motor while the winding are reconfigured via
external switching
When a motor is driven by the supply either at full speed or at part speed there is a rotating
magnetic field in the stator This field is rotating at line frequency The flux from the stator field
induces a current in the rotor and this in turn results in a rotor magnetic field
When the motor is disconnected from the supply (open transition) there is a spinning rotor within
the stator and the rotor has a magnetic field Due to the low impedance of the rotor circuit the time
constant is quite long and the action of the spinning rotor field within the stator is that of a
generator which generates voltage at a frequency determined by the speed of the rotor When the
motor is reconnected to the supply it is reclosing onto an unsynchronized generator and this result
in a very high current and torque transient The magnitude of the transient is dependent on the
phase relationship between the generated voltage and the line voltage at the point of closure can
be much higher than DOL current and torque and can result in electrical and mechanical damage
Open transition starting is the easiest to implement in terms or cost and circuitry and if the timing
of the changeover is good this method can work well In practice though it is difficult to set the
necessary timing to operate correctly and disconnectionreconnection of the supply can cause
significant voltagecurrent transients
In Open transition there are Four states
23 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 OFF State All Contactors are open
2 Star State The Main [KM3] and the Star [KM1] contactors are closed and the delta [KM2]
contactor is open The motor is connected in star and will produce one third of DOL torque at one
third of DOL current
3 Open State This type of operation is called open transition switching because there is an
open state between the star state and the delta state The Main contractor is closed and the Delta
and Star contactors are open There is voltage on one end of the motor windings but the other end
is open so no current can flow The motor has a spinning rotor and behaves like a generator
4 Delta State The Main and the Delta contactors are closed The Star contactor is open The
motor is connected to full line voltage and full power and torque are available
(2) Closed Transition StarDelta Starter
There is a technique to reduce the magnitude of the switching transients This requires the use of a
fourth contactor and a set of three resistors The resistors must be sized such that considerable
current is able to flow in the motor windings while they are in circuit
The auxiliary contactor and resistors are connected across the delta contactor In operation just
before the star contactor opens the auxiliary contactor closes resulting in current flow via the
resistors into the star connection Once the star contactor opens current is able to flow round
through the motor windings to the supply via the resistors These resistors are then shorted by the
delta contactor If the resistance of the resistors is too high they will not swamp the voltage
generated by the motor and will serve no purpose
In closed transition the power is maintained to the motor at all time This is achieved by
introducing resistors to take up the current flow during the winding changeover A fourth
contractor is required to place the resistor in circuit before opening the star contactor and then
removing the resistors once the delta contactor is closed These resistors need to be sized to carry
the motor current In addition to requiring more switching devices the control circuit is more
complicated due to the need to carry out resistor switching
In Close transition there are Four states
1 OFF State All Contactors are open
2 Star State The Main [KM3] and the Star [KM1] contactors are closed and the delta [KM2]
contactor is open The motor is connected in star and will produce one third of DOL torque at one
third of DOL current
Star Transition State The motor is connected in star and the resistors are connected across the
delta contactor via the aux [KM4] contactor
24 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Closed Transition State The Main [KM3] contactor is closed and the Delta [KM2] and Star
[KM1] contactors are open Current flows through the motor windings and the transition resistors
via KM4
Delta State The Main and the Delta contactors are closed The transition resistors are shorted out
The Star contactor is open The motor is connected to full line voltage and full power and torque
are available
Effect of Transient in Starter (Open Transient starter)
It is Important the pause between star contactor switch off and Delta contactor switch is on correct
This is because Star contactor must be reliably disconnected before Delta contactor is activated It
is also important that the switch over pause is not too long
For 415v Star Connection voltage is effectively reduced to 58 or 240v The equivalent of 33
that is obtained with Direct Online (DOL) starting
If Star connection has sufficient torque to run up to 75 or 80 of full load speed then the motor
can be connected in Delta mode
When connected to Delta configuration the phase voltage increases by a ratio of V3 or 173 The
phase currents increase by the same ratio The line current increases three times its value in star
connection
During transition period of switchover the motor must be free running with little deceleration
While this is happening ldquoCoastingrdquo it may generate a voltage of its own and on connection to the
supply this voltage can randomly add to or subtract from the applied line voltage This is known as
transient current Only lasting a few milliseconds it causes voltage surges and spikes Known as
a changeover transient
Size of each part of Star-Delta starter
(1) Size of Over Load Relay
For a star-delta starter there is a possibility to place the overload protection in two positions in the
line or in the windings
Overload Relay in Line
In the line is the same as just putting the overload before the motor as with a DOL starter
The rating of Overload (In Line) = FLC of Motor
Disadvantage If the overload is set to FLC then it is not protecting the motor while it is in delta
(setting is x1732 too high)
Overload Relay in Winding
25 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
In the windings means that the overload is placed after the point where the wiring to the contactors
are split into main and delta The overload then always measures the current inside the windings
The setting of Overload Relay (In Winding) =058 X FLC (line current)
Disadvantage We must use separate short circuit and overload protections
(2) Size of Main and Delta Contractor
1 There are two contactors that are close during run often referred to as the main contractor and
the delta contactor These are AC3 rated at 58 of the current rating of the motor
Size of Main Contactor= IFL x 058
(3) Size of Star Contractor
The third contactor is the star contactor and that only carries star current while the motor is
connected in star The current in star is 1 radic3= (58) of the current in delta so this contactor can
be AC3 rated at one third (33) of the motor rating
Size of Star Contactor= IFL x 033
Motor Starting Characteristics of Star-Delta Starter
Available starting current 33 Full Load Current
Peak starting current 13 to 26 Full Load Current
Peak starting torque 33 Full Load Torque
Advantages of Star-Delta starter
The operation of the star-delta method is simple and rugged
It is relatively cheap compared to other reduced voltage methods
Good TorqueCurrent Performance
It draws 2 times starting current of the full load ampere of the motor connected
Disadvantages of Star-Delta starter
Low Starting Torque (Torque = (Square of Voltage) is also reduce)
Break In Supply ndash Possible Transients
Six Terminal Motor Required (Delta Connected)
It requires 2 set of cables from starter to motor
It provides only 33 starting torque and if the load connected to the subject motor requires higher
starting torque at the time of starting than very heavy transients and stresses are produced while
changing from star to delta connections and because of these transients and stresses many
electrical and mechanical break-down occurs
26 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
In this method of starting initially motor is connected in star and then after change over the motor
is connected in delta The delta of motor is formed in starter and not on motor terminals
High transmission and current peaks When starting up pumps and fans for example the load
torque is low at the beginning of the start and increases with the square of the speed When
reaching approx 80-85 of the motor rated speed the load torque is equal to the motor torque and
the acceleration ceases To reach the rated speed a switch over to delta position is necessary and
this will very often result in high transmission and current peaks In some cases the current peak
can reach a value that is even bigger than for a DOL start
Applications with a load torque higher than 50 of the motor rated torque will not be able to start
using the start-delta starter
Low Starting Torque The star-delta (wye-delta) starting method controls whether the lead
connections from the motor are configured in a star or delta electrical connection The initial
connection should be in the star pattern that results in a reduction of the line voltage by a factor of
1radic3 (577) to the motor and the current is reduced to 13 of the current at full voltage but the
starting torque is also reduced 13 to 15 of the DOL starting torque
The transition from star to delta transition usually occurs once nominal speed is reached but is
sometimes performed as low as 50 of nominal speed which make transient Sparks
Features of star-delta starting
1 For low- to high-power three-phase motors
2 Reduced starting current
3 Six connection cables
4 Reduced starting torque
5 Current peak on changeover from star to delta
6 Mechanical load on changeover from star to delta
Application of Star-Delta Starter
The star-delta method is usually only applied to low to medium voltage and light starting
Torque motors
The received starting current is about 30 of the starting current during direct on line start and the
starting torque is reduced to about 25 of the torque available at a DOL start This starting
method only works when the application is light loaded during the start If the motor is too heavily
27 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
loaded there will not be enough torque to accelerate the motor up to speed before switching over
to the delta position
LESSON 1 WIRING SYSTEM OF SINGLE PHASE DISTRIBUTION BOARD
Introduction
28 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
29 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
30 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
31 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 2 WIRING SYSTEM OF SINGLE PHASE LIGHTING CIRCUIT Introduction
Objectives
1 Identify component and the specification
2 Wire component according to the schematic diagram
3 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Wiring bay Perforated metal 180 cm x 180 cm 1
2 Cut out fuse 63 A 240 V 1
3 Neutral link 1
4 Single pole one way switch cw
switch box
5A 240Vac 4
5 single pole two way switch cw
switch box
5A 240Vac 2
6 RCCB In = 40 A Tripping current
100mA240 Vac 50 Hz
1
7 Main switch 32 A 240V 1
8 kWatthour meter 40 A 240 Vac 1
9 Single pole MCB 6A 240 Vac 1
10 Self tapping Wood screw As required
11 DIN rail 35 mm width As required
32 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
12 PVC trunking 50 mm x 50 mm As required
13 Terminal blocks 5 A As required
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
1 One way switch to control one lamp
2 One way switch to control two lamps
3 Two of two way switch to control one lamp
4 Two of single pole two way switch and one of an intermediate switch to control one
lamp
5 One unit of ceiling fan and fan regulator to be controlled by one way switch
4 Test the functionality of completed project
LESSON 3ndash WIRING SYSTEM OF SINGLE PHASE POWER CIRCUIT Introduction
33 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
34 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify types of component and its specification
2 Wire component according to the schematic diagram given
3 Test the functionality of the circuit dead circuit test life circuit test
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board Perforated Metal 1
2 kWh meter 240 V 40 A 1
3 Socket outlet 13A 240Vac 4
4 RCCB 40A Trip Amps
30mA240 Vac
1
5 3 pin socket 240Vac 13A 4
6 Single pole MCB 20A 240 V 2
7 DOL starter 1 kW 240Vac 2
8 1 phase induction motor 2Hp 240 Vac 1
9 Cooker control unit 4kW 240Vac 1
10 Water heater point 4kW 240 Vac 1
11 DIN rail 35 mm As required
12 PVC casing 20mm As required
13 Flexible wires 05 mm As required
14 Terminal block 10 A As required
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Wire two unit of 13 A socket outlet in radial circuit
3 Wire four units of 13 A socket outlet in ring circuit
4 Wire one unit DOL starter for air-conditioner point
5 Wire one unit of cooker control unit point
6 Wire one unit of water heater point
7 Test the functionality of each component by using mmeter or power supply whichever
applicable
8 Wire component according to circuit diagram
9 Test the functionality of completed project dead circuit test life circuit test
Note
35 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Ensure that the correct rating of protection device and size of wire used
LESSON 4ndash CONDUIT BENDING AND TRUNKING FABRICATION TECHNIQUE
Common fitting used in an industrial wiring
Cutting and threading the condute
36 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
37 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
38 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify conduit fitting and the specification
2 Measure and Cut steel conduit according to specified dimension
3 Bend and fabricate conduit at 45 90 according to layout diagram
4 Wire component according to the schematic diagram
5 Test the functionality of the circuit
39 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Conduit Bender Oslash 19 mm ( frac34 ldquo) 1
2 Measuring Tape 3 metre 1
3 Hacksaw frame and blade 30cm 1
4 Conduit cutter 1
5 Pipe Vise 1
6 Pipe Wrench 1
7 Ratchet Dies 20 mm 1
8 Metal trunking 50 mm x 50 mm 1
9 GI conduit 20mm 1
10 End box 20 mm 1
11 Flexible wires 05 mm As required
12 Connectors 5 A As required
13 Single core PVC ins Cable 25 mm 2 As required
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Wire two unit of 13 A socket outlet in radial circuit
3 Wire four unit of 13 A socket outlet in ring circuit
4 Wire one unit DOL starter for air-conditioner point
5 Wire one unit of cooker control unit point
6 Wire one unit of water heater point
7 Test the functionality of each component by using multimeter or power supply whichever
applicable
8 Wire component according to circuit diagram
9 Test the functionality of completed project
Note
Ensure that the rating of protection device and size of wire
K prior to 31 March
2004 (BS 7671)
(formerly)
bare conductor
sleeved at terminations (formerly)
40 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 5 ndashWIRING SYSTEM OF 1 Oslash LIGHTING AND POWER CIRCUIT
POWER CIRCUITSa Radial circuits
Radial circuits are arranged in the same way as item 1 above in lighting layouts in that each socket
outlet is supplied via the previous one
Points to note
1 The number of socket outlets complying with BS 1363 is unlimited for a floor area of up to 50m 2 if
the circuit protection is a 30 A or 32 A cartridge fuse or circuit breaker the cable being 4 mm PVC
copper or 25 mm2 mineral insulated (mi)
2 The number of socket outlets is unlimited for a floor area up to 20 m 2 with any type of circuit
protection of 20 A using 25 mm2 PVC copper cable or 15 mm2 mi
3 The total number of fused spurs is unlimited
b ring final circuits
These circuits are the same as radial circuits except that the final socket outlet is wired back to the
supply position In effect any outlet is supplied from two directions (Fig 152)
Points to note
1 Every twin-socket outlet counts as two single-socket outlets
2 The number of non-fused spurs must not exceed the total number of points on the ring Fig 158
shows seven points on the ring and five spurs
3 The fuse rating of a fused spur box must not exceed 13 A and the current rating of all points supplied
by the fused spur must not exceed 13 A
4 Non-fused spurs must supply no more than one single or one double socket on the ring Fig 158
shows seven points on the ring and five spurs rating of all points supplied by the fused spur must not
exceed 13 A or one stationary appliance
CapacityMain conductor size
copper (mm2)
Earth conductor
size (mm2)
Circuit breaker
capacity (A)
Up to 600 W 15 15 6
600ndash1200 W 1525 15 10
1200ndash1800 W 254 25 16
41 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Ring circuit
(floor area 100 m2)25 15 3032
A2 radial circuit
(floor area 75 m2)40 25 3032
A3 radial circuit
(floor area 50 m2)25 15 20
Air conditioner (15 tonne) 60 60 3032
Cooker 60 60 3032
Water heater 40 40 20
Objectives
1 Identify component and the specification
2 Wire component according to the schematic diagram
3 Test the functionality of the circuit
42 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board Perforated 1
2 Cut out fuse and neutral link 60A 240V 1each
3 kWh meter 240V 40A 1
4 Switched Socket outlet 13A 240Vac 4
5 Single pole two way switch cw switch
box
5A 240Vac 2
6 RCCB ELCB 63 A Tripping current 100mA
415 Vac
1
7 3 pin plug 240Vac 13A 4
8 Single pole MCB 20 A 2
9 Single pole MCB 6A 1
10 Single pole MCB 20A 2
11 DOL starter 240Vac 2
12 1 phase induction motor 2hp 240 Vac 1
13 Self tapping Wood screw As required
14 DIN rail Stainless steel allum35 mm As required
15 PVC pipe 20mm dia As required
16 End box 20 mm dia 4
17 Flexible wires 05 mm 2 As required
18 Connectors 5 A As required
Procedures
43 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
4 Test the functionality of completed project
LESSON 6 ndash WIRING SYSTEM OF 3 Oslash DISTRIBUTION BOARD
Introduction
44 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
45 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
46 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
47 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
48 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify each component and the specification
2 Wire component according to the schematic diagram given
3 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting Board 450 x 600 mm Perforated metal 1
2 5 pin round socket and plug 415V ac 32A 1
3 Cut out fuse 60 A 3
4 Neutral link 1
5 kWatt hour meter 415V 60A 1
6 ELCB RCCB 3P+N In=63A415 Vac I trip= 300mA 1
7 ELCB RCCB 3P+N In=63A415 Vac I trip= 30mA 1
8 Single pole MCB 6A 240 V 3
9 Single pole MCB 20A 240 V 3
10 DOL starter 20 A 240Vac 2
11 Socket outlet 15 A 240 Vac 1
12 Switched Socket outlet 13 A 240 Vac 3
13 Led indicating light 5A 240 Vac 3
14 Single pole 4 gang 1 way switch 5A 240 Vac 2
15 Single pole 2 way switch 5A 240 Vac 2
16 1 phase induction motor 1 kW 240Vac 1
17 Metal trunking 30 mm x30 mm As required
18 Self tapping Wood screw 4 mm x 20 mm As required
19 DIN rail 25 mm x 1mm
20 GI steel rigid conduit 20mm As required
21 Flexible conduit 20mm As required
22 End box 20 mm 4
23 Flexible wires 05 mm 2 As required
24 Single core PVC insulated wire 15 mm 2 As required
25 Single core PVC insulated wires 25 mm 2 As required
26 Terminal block 10 A As required
Procedures
49 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify each components and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
4 Test the functionality of completed project
1 dead circuit test
2 life circuit
Note Proper earthing should be made
50 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 7 ndash WIRING SYSTEM OF THREE PHASE LIGHTING AND POWER CIRCUIT
51 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
52 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify component and the specification
2 Wire component according to the schematic diagram
3 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting bay Board Perforated metal 180 cm x 180 cm 1
2 k Watt hour meter 415V 60A 1
3 MCCB 415V 60A
4 ELCB RCCB In=60A415 Vac I trip=30mA 1
5 5 pin round Socket and
plug
415Vac 32A 4
6 Single pole MCB 6A 1
7 Triple pole MCB 20A 2
8 Triple pole Main switch 60A 1
9 DOL starter 240Vac 2
10 3 phase induction motor 2hp 415 Vac 1
11 1 phase induction motor 1
12 Metal trunking 30 mm x30 mm As required
13 Self tapping Wood screw 4 mm x 20 mm As required
14 DIN rail 25 mm x 1mm
15 GI steel rigid conduit 20mm As required
16 Flexible conduit 20mm As required
17 End box 20 mm 4
18 Flexible wires 05 mm As required
19 Connectors 10 A As required
Procedures
1 Identify each components and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
4 Test the functionality of completed project
1 dead circuit 2 life circuit test
5 Record the current drawn by the load as connected in star and delta
Note Proper earthing should be made
53 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 8 INSPECTION AND TESTING OF ELECTRICAL INSTALLATION
On completion of a wiring installation a number of tests on the installation have to be conducted to
ascertain that the wiring circuits and connected appliances are safe for use Prior to carrying out the
tests an inspection has to be done The results of the inspectionsupervision and test have to be
presented in Form G (as in Appendix IV) and Form H (as in Appendix V)
To have the test certification as in Form H the following tests shall be conducted
i Continuity Test
ii Insulation Resistance Test
iii Polarity Test
iv Earth Electrode Resistance test and
v Residual Current Device Test
1 Continuity Test
There are 3 main types of continuity tests for the final circuits-
i Protection Conductor Continuity Test
ii Final Ring Circuit Conductor Continuity Test
iii Live and Neutral Conductor Continuity Test
a) Protection Conductor Continuity Test
bull To ascertain that all protection conductors are connected in the correct and effective manner
bull Test equipment ndash Multimeter (Ohm range) or Ohm meter
54 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
bull Test Method
1 1048766 Ensure that the main switch RCD and MCB are open circuited (switched off) and all loads
are disconnected
2 1048766 Connected the test leads as in the Figure 81 The meter reading shall be less than 1 Ω
55 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Final Ring Circuit Conductor Continuity Test
bull To ensure that all conductors around the ring circuit have continuity
bull Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
bull Test Method
1 1048766 Disconnect both the supply source live conductors from the MCB the neutral conductor
from the neutral terminals and the earth conductor from the earth terminal in the distribution
fuse box
2 1048766 Connect the test leads as in the Figure 82 (EE)
3 1048766 Repeat the procedure for (L-L) and (N-N)
4 1048766 The meter reading value shall be less than 1 ohm
56 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Live and Neutral Conductor Continuity Test
a To ensure that each conductor in the circuit has continuity
b Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
2 Test Method
1 1048766 Switch off the Main switch RCD and MCB
2 1048766 Disconnect all loads
3 1048766 Switch on all switches in the circuit
4 1048766 Disconnect the fusesfinal circuit breakers and close the circuit
5 1048766 Carry out the test as shown in Figure 83
6 1048766 The meter reading value shall be less than 1Ω
57 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
58 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
CONTINUITY TEST
Insulation Resistance Test
i Ensure that there is no leakage current between phase conductors phase and neutral conductors and
phase conductor and earth
ii Test the strength of the cable insulation
iii Test Equipment ndash Insulation Resistance Tester operating voltage is 250VDC or 500VDC
iv Test Method
1 1048766 Switch off main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
59 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
4 1048766 Carry out test as in the Table below
5 1048766 Meter reading value shall be less than 1 Megaohm
60 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
61 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Insulation resitance test
62 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
INSULATION RESISTANCE TEST BETWEEN CONDUCTORS AND OPPOSITE POLARITY
Polarity Testi Ensure that each fuse or single pole control and protection device is connected only in the phase
conductor
ii Intermediate contact of Edison screw lamp holder is connected to the phase conductor
iii Ensure that phase neutral and earth conductors at socket outlets are connected at the correct
terminals
iv Test Equipment ndash Multimeter (Ohm range) or Ohm meter
v Test Method
1 1048766 Switch off Main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in Figure 85
63 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
5 1048766 Test switches and single phase control devices at the phase conductors
6 1048766 Test socket outlet connection sources
7 1048766 Test Edison screw lamp holder connections
8 1048766 Meter reading value shall be less than 1 Ω
64 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Polarity test
65 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Earth Electrode Resistance Testi To test the earth electrode resistance
ii To ascertain the suitability of the location of the electrode
iii To ensure that the electrode is not buried within the resistance area of another electrode
iv Test equipment ndash Earth Resistance Tester
v Test method -
1 1048766 Terminal rsquoErsquo is connected to the electrode to be tested (green conductor)
2 1048766 Terminal lsquoPrsquo is connected to the potential spike (yellow conductor) at a distance of 10
meters from the earth electrode
3 1048766 Terminal lsquoCrsquo is connected to the current spike (red conductor) at a distance of 20 meters
from the earth electrode
Earth Electrode Resistance Measurement Method (Figure 86)
This test must be repeated at least three times to ensure that the reading is not affected by interacting
earthing regions
i Record the first reading (Z1) Example Z1 = 10 Ω
ii Move the voltage spike to a distance of 6 meters from the original position Record the second
reading (Z2 ) Example Z2 = 10 Ω
iii Move the voltage spike to a distance of 6 meters from the original position Record the third
reading (Z3) Example Z3 = 10 Ω
66 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Residual Current Device Testi Ensure that the residual current device (RCD) trips within the set time on the occurrence of current
leakage to earth
ii Test Equipment ndash RCD Tester RCCB Tester
iii Test Method 1
1 1048766 Use the Trip Test Button
2 1048766 Press the trip button found on the RCD to determine if it trips or otherwise This test would
not be able to determine the sensitivity of the RCD nor the time taken for it to trip
iv Test Method 2
i 1048766 Use a RCD Tester
ii This equipment is equipped with a 13A plug which can be connected to a 13A socket outlet
Select the RCD sensitivity to be the same as the sensitivity of the RCD to be tested to
determine if the RCD can trip The time to trip shall not exceed 40 mS
iii 1048766 Test method ndash
a) Position the selection switch in accordance with the sensitivity of the RCD used
Example 100 mA 01 A
b) Position the operations switch to lsquoNo Triprsquo (frac12 Rated mA = 50) connect the 3 pin plug to
the 13A socket outlet
67 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
c) Switch on the 13A socket outlet ndash ensure that the P-N and P-E lights light up
This shows that the polarity is correct (Note if both the lights as above do not light up the test cannot
be continued)
d) Press the test button ndash the reading shows less than 200 mS and simultaneously the lsquotestrsquo light lights
up and the P-N and P-E lights do not light up At that instant the RCD will not trip
e) Move the selection switch to 180o (+ve wave) ndash repeat steps (d) and (e) Move the operations
switch to lsquoTriprsquo (Rated mA = 100)
g) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200mS
h) Move the selection switch to 0o (-ve wave)
i) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
j) The above test is repeated until a near correct reading is obtained
k) Record the test results
l) Change the operations switch to lsquoFast Triprsquo and press the test button ndash RCD will trip within a
time not exceeding 40 millisecond
m) Repeat a number of times at 0o or 180o
On completion of a wiring installation a number of tests on the installation have to be conducted to
ascertain that the wiring circuits and connected appliances are safe for use Prior to carrying out the
tests an inspection has to be done the following tests shall be conducted
i Continuity Test
ii Insulation Resistance Test
iii Polarity Test
iv Earth Electrode Resistance test and
v Residual Current Device Test
821 Continuity Test
There are 3 main types of continuity tests for the final circuits-
i Protection Conductor Continuity Test
ii Final Ring Circuit Conductor Continuity Test
68 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
iii Live and Neutral Conductor Continuity Test
a) Protection Conductor Continuity Test
bull To ascertain that all protection conductors are connected in the correct and effective manner
bull Test equipment ndash Multimeter (Ohm range) or Ohm meter
bull Test Method
1 1048766 Ensure that the main switch RCD and MCB are open circuited (switched off) and all loads are
disconnected
2 1048766 Connected the test leads as in the Figure 81
3 1048766 The meter reading shall be less than 1 Ω
Final Ring Circuit Conductor Continuity Test
bull To ensure that all conductors around the ring circuit have continuity
bull Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
bull Test Method
1 1048766 Disconnect both the supply source live conductors from the MCB the neutral conductor
from the neutral terminals and the earth conductor from the earth terminal in the distribution
fuse box
2 1048766 Connect the test leads as in the Figure 82 (EE)
3 1048766 Repeat the procedure for (L-L) and (N-N)
4 1048766 The meter reading value shall be less than 1 ohm Figure 82 - Final Ring Circuit Conductor
Continuity Test Ohm Meter
Disconnect both the supply source cables from mcbfuse
Take readings at earth conductors of both sources and note resistance readings
Live and Neutral Conductor Continuity Test
1 To ensure that each conductor in the circuit has continuity
2 Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
3 Test Method
1 1048766 Switch off the Main switch RCD and MCB
2 1048766 Disconnect all loads
3 1048766 Switch on all switches in the circuit
4 1048766 Disconnect the fusesfinal circuit breakers and close the circuit
5 1048766 Carry out the test as shown in Figure 83
6 1048766 The meter reading value shall be less than 1 ohm Figure 83 - Live and Neutral
Conductor Continuity Test Ohm Meter
Insulation Resistance Test
69 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
i Ensure that there is no leakage current between phase conductors phase and neutral conductors and
phase conductor and earth
ii Test the strength of the cable insulation
iii Test Equipment ndash Insulation Resistance Tester Operating voltage is 250VDC or 500VDC
iv Test Method
1 1048766 Switch off main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in the Table below
5 1048766 Meter reading value shall be less than 1 Megaohm
Polarity Test
i Ensure that each fuse or single pole control and protection device is connected only in the phase
conductor
ii Intermediate contact of Edison screw lamp holder is connected to the phase conductor
iii Ensure that phase neutral and earth conductors at socket outlets are connected at the correct
terminals
iv Test Equipment ndash Multimeter (Ohm range) or Ohm meter
v Test Method
1 1048766 Switch off Main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in Figure 85
5 1048766 Test switches and single phase control devices at the phase conductors
6 1048766 Test socket outlet connection sources
7 1048766 Test Edison screw lamp holder connections
8 1048766 Meter reading value shall be less than 1 Ω
Earth Electrode Resistance Test
i To test the earth electrode resistance
70 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
ii To ascertain the suitability of the location of the electrode
iii To ensure that the electrode is not buried within the resistance area of another electrode
iv Test equipment ndash Earth Resistance Tester
v Test method -
1 1048766 Terminal rsquoErsquo is connected to the electrode to be tested (green conductor)
2 1048766 Terminal lsquoPrsquo is connected to the potential spike (yellow conductor) at a distance of 10
meters from the earth electrode
3 1048766 Terminal lsquoCrsquo is connected to the current spike (red conductor) at a distance of 20 meters
from the earth electrode E P C Electrode 10 meter 10 meter
Figure 86 ndash Earth Electrode Resistance Measurement Test Equipment
Earth Electrode Resistance Measurement Method (Figure 86)
This test must be repeated at least three times to ensure that the reading is not affected by interacting
earthing regions
i Record the first reading (Z1) Example Z1 = 10 Ω
ii Move the voltage spike to a distance of 6 meters from the original position Record the second
reading (Z2) Example Z2 = 10 Ω
iii Move the voltage spike to a distance of 6 meters from the original position Record the third
reading (Z3)
Example Z3 = 10 Ω
Residual Current Device Test
71 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
i Ensure that the residual current device (RCD) trips within the set time on the occurrence of current
leakage to earth
ii Test Equipment ndash RCD Tester RCCB Tester
iii Test Method 1
1 1048766 Use the Trip Test Button
2 1048766 Press the trip button found on the RCD to determine if it trips or otherwise This test would
not be able to determine the sensitivity of the RCD nor the time taken for it to trip
iv Test Method 2
1048766 Use a RCD Tester
This equipment is equipped with a 13A plug which can be connected to a 13A socket outlet Select the
RCD sensitivity to be the same as the sensitivity of the RCD to be tested to determine if the RCD can
trip The time to trip shall not exceed 40 mS
1048766 Test method ndash
a) Position the selection switch in accordance with the sensitivity of the RCD used
Example 100 mA 01 A
b) Position the operations switch to lsquoNo Triprsquo (frac12 Rated mA = 50) connect the 3 pin plug to
the 13A socket outlet
c) Switch on the 13A socket outlet ndash ensure that the P-N and P-E lights light up This shows that
the polarity is correct (Note if both the lights as above do not light up the test cannot be
continued)
d) Press the test button ndash the reading shows less than 200 millisecond and simultaneously the
lsquotestrsquo light lights up and the P-N and P-E lights do not light up At that instant the RCD will
not trip
e) Move the selection switch to 180o (+ve wave) ndash repeat steps (d) and (e) = 100)
f) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
g) Move the selection switch to 0o (-ve wave)
h) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
i) The above test is repeated until a near correct reading is obtained
j) Record the test results
k) Change the operations switch to lsquoFast Triprsquo and press the test button ndash RCD will trip within a
time not exceeding 40 mS
l) Repeat a number of times at 0o or 180o
72 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 9 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (DC)
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
73 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Start stop button 240Vac 5A 2
9 Filament lamp (Bulb ) 240Vac 40W 3
10 Overload Relay 415V 20A 3
11 Three phase induction motor 5 hp 3
12 Single phase step down transformer 2500VA 1
13 Single core PVC insulated Cable 1mm 2 As required
14 Single core PVC insulated Cable 25mm 2 As required
15 DIN rail 35 mm As required
16 PVC type Cable tray 50 mm x 50 mm As required
17 Cable ties 4 ldquo As required
18 Flexible wires 05 mm As required
19 PVC Connectors 5 A amp 20 A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the schematic
diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a optional exercise
i Simple DOL starter
ii Forward reverse DOL starter
iii Forward Reverse Dahlander motor
iv Three motors operated in sequence by DOL starter operated by manual push
button or time delay relay
74 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
a One loop per-cycle
b Continuous operation in a loop
c optional circuit design to represent the same task
v Only one out of three motors to be operated at a time (quiz)
4 Test the functionality of completed project
LESSON 10 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (AC)
75 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 1
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Lamp point 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
76 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
11 Overload Relay 415V 20A 3
12 Three phase induction
motor
5 hp 3
13 Single core PVC insulated
Cable
1mm 2 As required
14 Single core PVC insulated
Cable
25mm 2 As required
15 DIN rail 35 mm As required
16 PVC type Cable tray 50 mm x 50 mm As required
17 Cable ties 4 ldquo As required
18 Flexible wires 05 mm As required
19 PVC Connectors 5 A amp 20 A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the
schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram optional exercise
4 Simple DOL starter
5 Forward reverse DOL starter
6 Test the functionality of completed project
77 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 1
78 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
cm
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Indicating light 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
11 Overload Relay 415V 20A 3
12 Three phase induction motor 5 hp 3
13 Single phase step down
transformer
2500VA 1
14 Single core PVC insulated
Cable
1mm 2 As required
15 Single core PVC insulated
Cable
25mm 2 As required
16 DIN rail 35 mm As required
17 PVC type Cable tray 50 mm x 50 mm As required
18 Cable ties 4 ldquo As required
19 Flexible wires 05 mm As required
20 PVC Connectors 5 A amp 20 A 240 V As required
21 Single pole MCB 6A 240 V 1
22 Single pole MCB 2A 240 V 1
23 Triple pole MCB 20A 415 V 1
24 Mounting board 30 cm x 40 cm x 3
cm
1
25 Relay cw 11 pin socket 10 A 240 Vac 2
26 Time delay relay 10 A 240 Vac 3
27 Triple pole Contactor 20A 240Vac 3
28 Batten type Lamp holder 240Vac 10 A 3
29 Start stop button 240Vac 10A 2
30 Indicating light (Bulb ) 240Vac 25W 3
31 Overload Relay 415V 20A 1
32 Three phase dahlander type
induction motor
5 hp 1
33 Single phase step down
transformer
24024Vac
2500VA
1
79 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
34 Single core PVC insulated
Cable
1mm 2 As required
35 Single core PVC insulated
Cable
25mm 2 As required
36 DIN rail 35 mm As required
37 PVC type Cable tray 50 mm x 50 mm As required
38 Cable ties 4 ldquo As required
39 Flexible wires 075 mm As required
40 PVC Connectors 5 A amp 20 A 240 V As required
41 Terminal block 20A 240Vac As required
Procedures
5 Identify each component according to specification and quantity required from the schematic
diagram attached
6 Test the functionality of each component by using multi-meter or power supply whichever
applicable
7 Wire component according to circuit diagram
8 Three motors operated in sequence by DOL starter operated by manual push button or time
delay relay
a One loop per-cycle
b Continuous operation in a loop
c optional circuit design to represent the same task
d Only one out of three motors to be operated at a time (quiz)
9 Test the functionality of completed project
80 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
BASIC DESIGN INDUSTRIAL MOTOR CONTROL (SEQUENCE CONTROL)
THREE PHASE INDUCTION MOTOR OPERATED IN SEQUENCE BY DIRECT ON LINE
STARTER
LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
81 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
82 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Lcd lamp indicator 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
11 Overload Relay 415V 20A 3
12 Three phase induction motor 5 hp 3
13 Single phase step down transformer 2500VA 1
14 Single core PVC insulated Cable 1mm 2 As required
15 Single core PVC insulated Cable 25mm 2 As required
16 DIN rail 35 mm As required
17 PVC type Cable tray 50 mm x 50 mm As required
18 Cable ties 4 ldquo As required
19 Flexible wires 1 mm Oslash As required
20 PVC Terminal block 10A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the schematic
diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a optional exercise
i Forward Reverse dahlander motor
4 Test the functionality of completed project
83 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
THREE PHASE DAHLANDER TYPE INDUCTION MOTOR OPERATED FORWARD AND
REVERSE OPERATION BY DIRECT ON LINE STARTER
84 ndash 99EASYTECH ENTERPRISE
LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
Introduction
If a motors windings are connected in the star configuration any two phases will be in series across
the supply and hence the line current will be smaller(by 577) than if the windings were connected in
the delta arrangement
Hence larger-type motors with heavy starting currents are first connected in star and then when the
starting currents fall in delta This of course means that all six of the ends of the windings must be
brought to terminations outside the casing (Fig 833)
EZTECH
EZTECH ELECTRICAL INSTALLATION GUIDE
The automatic version of this starter incorporates a timing relay which automatically changes the
connections from star to delta Figs 834 and 835 show the wiring and schematic diagrams for a star
delta starter
Objectives
1 Identify component and the specification
2 Design forward reverse star delta starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
2 ndash 99EASYTECH ENTERPRISE
REV -C
LEGENDMCCB Moulded Case Circuit BreakerTOR Thermal Over Load RelayFOW-C Mains Forward ContactorREV-C Mains Reverse ContactorDC Delta ContactorSC Star ContactorS-SW Mains Selector Switch
SC
V2
W2
U2
DC
V1
W1
U1
TOR
TOR
FOW-C
30A MCCB
TOR
MAIN CIRCUIT FORWARD REVERSE STAR DELTA
RYBN S
-SW
3 PHASEINDUCTION MOTOR
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Relay 10 A 240V 3
5 Triple pole Contactor
6 cw NO NC auxiliary contact
240Vac 20 A 4
7 Overload Relay 415 V 1
8 LED indicator 240vac 5 A 4
9 Start stop button 240Vac 5A 2
10 DIN rail 35 mm As required
11 Flexible wires 1 mm As required
12 Single core PVC insulated
wire
25 mm As required
13 Terminal block 20 A As required
14 Squirrel cage motor 5kW 1
15 5 pin plug and socket 415V 20A 1
16 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
3 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
a Manual star delta
b Manual Forward reverse star delta starter
c Automatic star delta starter
d Automatic Forward reverse star delta starter
4 Test the functionality of completed project
4 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
Objectives
1 Identify component and the specification
2 Design auto transformer starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
5 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Autotransformer starter is used to start a 3 phase induction motor that has a rating between 10 to 15 hp
6 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Autotransformer set 10Kw 415 V 50 Hz 1
5 Triple pole Contactor 240Vac 4
6 Batten type Lamp holder 240 Vac 105 A 4
7 Start stop button 240Vac 10A 4
8 Filament lamp (Bulb ) 240Vac 40W 4
9 DIN rail 35 mm As required
10 Flexible wires 1 mm As required
7 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
11 Single core PVC insulated
wire
25 mm As required
12 Terminal block 20 A As required
13 Squirrel cage motor 10kW 1
14 5 pin plug and socket 415V 20A 1
15 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a open transient autotransformer starter
b close transient autotransformer starter
c Forward reverse autotransformer starter
4 Test the functionality of completed project
8 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
Objectives
1 Identify component and the specification
2 Design rotor resistance starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
9 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Rotor Resistor set 10kW 1
5 Triple pole Contactor 240Vac 20A 4
6 Indicating light 240vac 5 A 4
7 Start stop push button 240Vac 5A 4
8 DIN rail 35 mm As required
9 Flexible wires 1 mm 2 As required
10 Single core PVC insulated wire 25 mm 2 As required
11 Terminal block 20 A As required
12 Slip Ring motor 10kW 1
13 5 pin round 3 phase socket 415V 20A 1
14 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
10 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
4 Test the functionality of completed project
a Dead circuit test b Life circuit test
5 Measure starting and running Amps
LESSON 16
TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
An installation in general will suffer damage
Damage usually occurs on the electric motor control as follows
1 Damage to the main circuit
2 Damage to the control circuit
The cause of the damage
i Overcurrent overload short circuit
ii Leakage current to ground
iii Equipment malfunction
iv The main control circuit
a Trip of main circuit protection devices fire
b Defect of motor terminal such as short circuit fire loose
v The control circuit is not functioning -
a contactor relay relay time overload relay does not work damaged burned
b Loose cable connection disconnected
Detecting and Repairing Damage
Examples of damage are as follows
i Motor does not work
ii Motor function and overload relay trips
iii Motor function but only partially functional control circuit
Methods of detecting damage
Among the known methods necessary to detect damage are as follows
1 Turn off the electricity at the main switch (main switch) in order to avoid any danger during the
work carried out to detect damage
2 Check all the protective gear that controls the motor control main circuit
11 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
3 Make sure the damage function control circuit
4 Check the control circuit according to the schematic circuit diagram of the motor control
5 Check the operation of the control circuit
Note
Use wiring that has been installed on the SYSTEM OF MOTOR CONTROL BOARD by Forward
Reverse control circuit for Star Delta to test and look for damage
SELF-ASSESSMENT QUESTIONS
1 (a) Explain what is meant by the term lsquoback emfrsquo in a motor
(b) Outline the basic differences between series shunt and compound wound dc motors
2 (a) With the aid of diagrams explain how the speed of series shunt and compound-wound motors
may be controlled
(b) A 440V dc shunt-wound motor has a field resistance of 200R and an armature resistance of 06 R
When its speed is 20 rev d second the current drawn from the supply is 122A Calculate its back
emf at this speed If the speed were decreased to 19 revssecond the field flux remaining unchanged
calculate the new back emf and the new armature current
3 A load of 64 kW at 240 V is supplied from the terminals of a shunt-wound dc generator The field
resistance is 180 A Calculate the armature current
4 (a) Explain with the aid of a diagram how a rotating magnetic field may be
(b) What is meant by lsquosynchronous speedrsquo
Calculate the synchronous obtained speed of a 12 pole motor if the supply frequency is 50Hz
5 (a) Explain the action of a synchronous motor
(b) What methods are available to start a synchronous motor Explain with diagrams
6 (a) Explain the action of a cage induction motor
(b) What is meant by the term lsquosliprsquo
Calculate the percentage slip of a six pole induction motor running at 162 revssecond from a 50 Hz
supply
7 Describe with sketches three different ways of starting a single-phase induction motor
12 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
8 Explain with the aid of a sketch the action of a three-phase DOL starter
What are dashpots used for How are remote start and stop buttons connected
9 A I0 kW 240V 50Hz single-phase cage rotor induction motor is 85efficient and has a PF of 068
lagging Calculate the motor current and the value of capacitor required to raise the PF to 093
lagging
10 Calculate the torque developed by an 18 kW four-pole induction motor run at 35 slip from a
50Hz supply
APPENDIX 1
13 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 11
14 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 111
Attachment Reference
httpswwwtlc-directcoukBook621htm
httpwwwstgovmyindexphpms
15 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
a) Switches socket outlets 3 pin plugs ceiling roses connectors sockets ndash construction material shall
be of polycarbonate type
iii For all wiring using metal conduits - Switches socket outlets and connectors ndash construction
material shall be of metal clad type and All accessories shall be effectively earthed
iv Switch fuse used in single phase installations shall have the fuse permanently connected and not
move with the fuse
v Fuse switch used in 3 phase domestic installations also has fuse and switch The fuse connector is
installed together to allow the fuse to move simultaneously with the switch
vi Lamp
a) Fluorescent lamps using magnetic ballasts (watt loss not exceeding 6 watts) shall be
equipped with dry paper type capacitor
b) Fluorescent lamps using electronic ballasts or high frequency electronic ballasts do not
need capacitors
c) Outdoor domestic lamp installations shall use weather proof and water proof lamps
d) Submerged light installations (example in swimming pools fountains etc) shall have water
proof lamps with a voltage not exceeding 12 Volt AC
vii Electric water heaters is divided into 2 types namely
1 instantaneous water heaters and
2 stored water heaters (storage tank type)
a) Instantaneous water heaters shall be equipped with a 2 pole control switch and its own
residual current device
b) Storage water heaters (storage tank type) shall be installed with an
Water heaters exceeding 3kW shall be permanently connected to a 20A30A rated circuit
breakerfuse with an isolator switch and residual current device
viii Electric cookers exceeding 3kW shall have its own circuit connected permanently to a 30A rated
circuit breaker or fuse with an isolator switch and cooker control unit incorporated with a 13A socket
outlet Two or more cooker appliances may be installed in the same room within a distance of 2
meters
ix Electric motors (fence gate air conditioners fountains swimming pools fish ponds water
pumps) exceeding 373W but not exceeding 2238W shall be connected permanently to a 20A30A
rated circuit breakerfuse together with an isolator motor starter and 15A socket outlet
14 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
The motor starter shall be of Direct-On-Line type with the appliance together with the contactor
overload relay and on-off control The circuit breakerfuse which controls the motor circuit shall be
capable of withstanding the starting current of the motor
x Electric bells ndash the circuit shall have a push button switch and a ACDC transformer
xi Ceiling fans shall conform to clause 21101 of the MS 12192002 standard with regards to test on
the suspension system of ceiling fans
EARTHING OF ELECTRICAL INSTALLATIONS51 Earthing
Earthing is a connection system between the metallic parts of an electrical wiring system and the
general mass of the earth This will provide an easy path with a low impedence or resistance to earth to
enable the protection system to operate effectively It will thus ensure safety to human
beingsconsumers from the dangers of electric shocks if earth leakage currents are present In general
an electrical installation is earthed because of -
i Safety reasons
ii Protection system requirements
iii Need to limit over voltages
iv Need to provide a path for electrical discharge
v Legal requirements
52 Classification of Earthing
Generally earthing can be divided into 2 parts namely -
i System Earthing
a To isolate the system under fault conditions
b To limit the potential difference between conductors which are not insulated in an area
c To limit the occurrence of over voltages under various conditions
ii Equipment Earthing
Equipment earthing is undertaken to protect human beingsconsumers If a live source comes into
contact with the equipment body electrical energy will flow to the earth without flowing through the
human being consumerrsquos body This is because of the fact that the human body has a greater
resistance compared with the resistance to earth
53 Types and Functions of Earthing Accessories
Earthing accessories are as follows -
i Earthing Electrode
Copper jacketed steel core rods are used as electrodes for domestic wiring
ii Equipotential Bonding
15 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
This is the conductor which is connected between the consumer earthing point and the exposed
metallic part The minimum cable size for this purpose is 10 mm2
iii Protection Conductor
This is the conductor which connects the consumer earthing point with other parts of the installation
which needs earthing Its size is as follows-
a) Same size as the phase cable up to a size of 16mm2
b) 16 mm2 if the phase cable size is between 16 mm2 and 35 mm2
c) Half the size of the phase cable if the size of the phase cable exceeds 35 mm2
54 Earthing Arrangements Using a TT System
i The first alphabet indicates the earthing arrangements from the supply side
ii The second alphabet indicates the earthing arrangement in the consumerrsquos installation
T ndash first Indicates that the supply system has its own earthing arrangements
T ndash second Indicates that all metallic frames of the electrical appliances etc are connected directly to
earth
Parts that are Required to be Earthed
i All metallic structures in the wiring system (non current carrying) such as metallic covers conduits
ducts the armour of catenary wires etc
ii A secondary winding point in a transformer and
iii Frame of metal roof truss
56 Parts that are not Required to be Earthed
i Short isolated metallic parts for mechanical protection of cables which have non metallic sheaths
other than conduits which are connected at entry points between the building and conduits which
protect discharge lamp cables
ii Cable clips for installing cables
iii Metallic covers for lamps
16 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
iv Small metallic parts such as screws and name plates which are isolated by means of insulation
v Metallic lamp parts for filament lamps in water proof floors
57 Termination to Earth
The termination to earth is done as shown in Figure 72
Earth Electrode Resistance
The maximum permitted earth electrode resistance for different types of installations is as shown in
the Table below
Earth electrode for installations protected by RCDs of sensitivity 100mA 10 Ω
Lightning arrestor earth electrode 10 Ω
Legal Requirements
i Sub regulation 12(1) and 12(2) of the Electricity Regulations 1994 state that any electrical wiring in
an installation shall be under the immediate supervision of a Wireman with Single Phase Restriction or
Three Phase Restriction Upon completion the Wireman shall certify a Supervision and Completion
Certificate
ii Sub regulation 13(1) and 13 (2) of the Electricity Regulations 1994 state that the installation shall
be tested by a Wireman with Single Phase Restriction or a Wireman with Three Phase Restriction
authorized to test any installation and who shall certify a Test Certificate for the installation
iii Sub regulation 14(1) of the Electricity Regulations 1994 states that the Supervision and
Completion Certificate and the Test Certificate as in regulations 12 and 13 shall be in Forms G and H
respectively as prescribed in the First Schedule
17 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
4 SAFETY REQUIREMENTS FOR ELECTRICAL WIRING WORKS IN RESIDENTIAL BUILDINGS
61 Safety Requirements
Safety requirements for electrical wiring works have to be followed to eliminate any accidents which
can result in physical damage or loss of life or property Failure to meet the safety regulations may
result in workers consumers or the public being inflicted with electrical shocks
In addition to this safety steps will also encourage workers or electricity consumers who are
disciplined and who always give importance to safety
62 Safety Steps
Safety requirements have to be followed whenever electrical works are undertaken in a residential
building
i Personal Safety
a Use suitable personal protection equipment as needed such as safety shoes gloves safety helmet
etc when at the work place
b Use safety clothing suitable for the work to be undertaken
c Do not wear jewellery or decorative items such as rings watches chains etc while carrying out
electrical works
ii Safety at the Work Place
a Acquire knowledge about the dangers of electrical works that is to be undertaken and how to deal
with those dangers
b Always adhere to the safety regulations which have been set for the work place
c Ensure that the electricity supply is switched off before carrying out the works
d Acquire the needed knowledge and practice a cautious and calm attitude while working ensure
cleanliness in and around fellow workers
e While working at elevated places the worker should always use suitable equipment such as wooden
or aluminium ladders iron scaffoldings or platforms safety belts or other equipment needed to ensure
that the work can be undertaken safely
f Use electrical equipment which is operational and safe to be used and ensure that the supply for it is
being supplied through a residual current device (RCD) with a sensitivity of 30 mA
g Ensure that exposed temporary supply electrical cables have mechanical protection
h If inflammable or corrosive material is present necessary safety steps have to be undertaken as
required by the relevant safety regulations
63 Dangers of Electrical Shocks
i Electrical Shock
Electrical shocks can occur due to direct or indirect contact
a Direct Contact
18 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Direct contact occurs when the worker or consumer receives an electrical shock on touching directly a
live conductor or cable
b Indirect Contact
Here the electric shock occurs due to contact with a part which is connected to the electrical
installation and not to a direct contact with a live cable or conductor possibly due to damages in the
appliance or insulation resulting in leakages of current
Why Electric Shocks Occura Unsafe Work Method or Action Undertaking Electrical Work Without Disconnecting the
Supply
Maintenance or circuit testing work done without disconnecting the supply will have a high possibility
of electrical shocks occurring
bull Not Following Safe Work Procedures
To eliminate the occurrence of electrical shocks each worker has to always follow safe work
procedures which are set by regulations and standards
b Defects in the Electrical System
i Leakage Current
Leakage currents or earth leakage currents can result in the metallic frames becoming live and
energised This can give rise to the danger of electrical shock to the worker consumer or the public if
they hold or come into contact with the metallic frame
ii Exposed Conductor or Disconnected Cable
Exposed conductors or cables which are broken and are alive (energised) can result in electrical shock
when touched The supply source must be immediately isolated or switched off and a report must be
made to the responsible entity
64 First Aid and Basic Pulmonary Resuscitation
i First Aid
First aid is the initial assistance given to a person who has met with an accident is sick or is injured to
prevent the condition of the victim from becoming more serious while awaiting the arrival of the
paramedics (ambulance) or before being brought to the hospital
i Pulmonary Resuscitation
Pulmonary resuscitation has to be undertaken to assist the victim who has breathing difficulties as a
result of being drowned receiving an electrical shock etc Pulmonary resuscitation has to be carried
out in accordance to the correct method as stated in the first aid manuals issued by accredited first aid
bodies
ii First Aid Box
19 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
A first aid box has to be provided by the building owner construction site supervisor or brought
personally by the worker under the supervision of the responsible person
65 Training Programme
The management shall conduct periodic training programmes for the workers with regards to work
safety on aspects including the following -
i Dangers of electrical work being undertaken and how to control those dangers
ii The safety regulations set for the work place and
iii First aid procedures
66 Fire Prevention
Fire Extinguisher A suitable functioning fire extinguisher to control fires has to be made available at
the work place at all times
67 Competent Person
The Electricity Regulations 1994 require that all electrical work has to be undertaken by or under the
direct supervision of a competent person registered with the Energy Commission Besides that the
electrical contractor undertaking the electrical work has also to be registered with the Energy
Commission The installation owner thus has to ensure that the appointed electrical contractor is
registered with the Energy Commission and that the registration is still valid
INSTALLATION CIRCUITS AND SYSTEMS1 Block diagrams
These show using squares rectangles etc the sequence of a system without too much technical detail
eg Figures 1517 and 1526
2 Layout diagrams
These are very similar to block diagrams but they indicate more technical detail and tend to show
items in their correct geographical location (eg Figures 1518 and 1519)
3 Circuitschematic
These show how a circuit functions and takes no account of exact locations of terminals or equipment
(eg Figures 1528 1529 1532 1534 etc)
4 Wiring diagram
These indicate how a circuit or system is physically wired (eg Figures 152 154 156 etc)
Most induction motors are started directly on line but when very large motors are started that way
they cause a disturbance of voltage on the supply lines due to large starting current surges To limit the
starting current surge large induction motors are started at reduced voltage and then have full supply
voltage reconnected when they run up to near rotated speed Two methods are used for reduction of
starting voltage are star delta starting and auto transformer stating
20 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Working Principal of Star-Delta Starter
This is the reduced voltage starting method Voltage reduction during star-delta starting is achieved by
physically reconfiguring the motor windings as illustrated in the figure below During starting the
motor windings are connected in star configuration and this reduces the voltage across each winding 3
This also reduces the torque by a factor of three After a period of time the winding are reconfigured as
delta and the motor runs normally
StarDelta starters are probably the most common reduced voltage starters They are used in
an attempt to reduce the start current applied to the motor during start as a means of reducing the
disturbances and interference on the electrical supply
Traditionally in many supply regions there has been a requirement to fit a reduced voltage
starter on all motors greater than 5HP (4KW) The StarDelta (or WyeDelta) starter is one of the
lowest cost electromechanical reduced voltage starters that can be applied
The StarDelta starter is manufactured from three contactors a timer and a thermal overload
The contactors are smaller than the single contactor used in a Direct on Line starter as they are
controlling winding currents only The currents through the winding are 1root 3 (58) of the
current in the line
There are two contactors that are close during run often referred to as the main contractor and
the delta contactor These are AC3 rated at 58 of the current rating of the motor The third
contactor is the star contactor and that only carries star current while the motor is connected in star
The current in star is one third of the current in delta so this contactor can be AC3 rated at one
third (33) of the motor rating
Star-delta Starter Consists following units
1) Contactors (Main star and delta contactors) 3 Norsquos (For Open State Starter) or 4 Norsquos (Close
Transient Starter)
2) Time relay (pull-in delayed) 1 No
3) Three-pole thermal over current release 1No
4) Fuse elements or automatic cut-outs for the main circuit 3 Nos
5) Fuse element or automatic cut-out for the control circuit 1No
Power Circuit of Star Delta Starter
1 The main circuit breaker serves as the main power supply switch that supplies electricity to the
power circuit
2 The main contactor connects the reference source voltage R Y B to the primary terminal of the
motor U1 V1 W1
21 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
3 In operation the Main Contactor (KM3) and the Star Contactor (KM1) are closed initially and
then after a period of time the star contactor is opened and then the delta contactor (KM2) is
closed The control of the contactors is by the timer (K1T) built into the starter The Star and Delta
are electrically interlocked and preferably mechanically interlocked as well In effect there are
four states
4 The star contactor serves to initially short the secondary terminal of the motor U2 V2 W2 for the
start sequence during the initial run of the motor from standstill This provides one third of DOL
current to the motor thus reducing the high inrush current inherent with large capacity motors at
startup
5 Controlling the interchanging star connection and delta connection of an AC induction motor is
achieved by means of a star delta or wye delta control circuit The control circuit consists of push
button switches auxiliary contacts and a timer
Control Circuit of Star-Delta Starter (Open Transition)
1 The ON push button starts the circuit by initially energizing Star Contactor Coil (KM1) of star
circuit and Timer Coil (KT) circuit
2 When Star Contactor Coil (KM1) energized Star Main and Auxiliary contactor change its
position from NO to NC
3 When Star Auxiliary Contactor (1)( which is placed on Main Contactor coil circuit )became
NO to NC itrsquos complete The Circuit of Main contactor Coil (KM3) so Main Contactor Coil
energized and Main Contactorrsquos Main and Auxiliary Contactor Change its Position from NO
To NC This sequence happens in a friction of time
4 After pushing the ON push button switch the auxiliary contact of the main contactor coil (2)
which is connected in parallel across the ON push button will become NO to NC thereby
providing a latch to hold the main contactor coil activated which eventually maintains the
control circuit active even after releasing the ON push button switch
5 When Star Main Contactor (KM1) close its connect Motor connects on STAR and itrsquos
connected in STAR until Time Delay Auxiliary contact KT (3) become NC to NO
6 Once the time delay is reached its specified Time the timerrsquos auxiliary contacts (KT)(3) in
Star Coil circuit will change its position from NC to NO and at the Same Time Auxiliary
contactor (KT) in Delta Coil Circuit(4) change its Position from NO To NC so Delta coil
energized and Delta Main Contactor becomes NO To NC Now Motor terminal connection
change from star to delta connection
7 A normally close auxiliary contact from both star and delta contactors (5amp6)are also placed
opposite of both star and delta contactor coils these interlock contacts serves as safety
switches to prevent simultaneous activation of both star and delta contactor coils so that one
22 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
cannot be activated without the other deactivated first Thus the delta contactor coil cannot be
active when the star contactor coil is active and similarly the star contactor coil cannot also
be active while the delta contactor coil is active
8 The control circuit above also provides two interrupting contacts to shutdown the motor
The OFF push button switch break the control circuit and the motor when necessary The
thermal overload contact is a protective device which automatically opens the STOP Control
circuit in case when motor overload current is detected by the thermal overload relay this is to
prevent burning of the motor in case of excessive load beyond the rated capacity of the motor
is detected by the thermal overload relay
9 At some point during starting it is necessary to change from a star connected winding to a
delta connected winding Power and control circuits can be arranged to this in one of two
ways ndash open transition or closed transition
What is Open or Closed Transition Starting
(1) Open Transition Starters
Discuss mention above is called open transition switching because there is an open state between
the star state and the delta state
In open transition the power is disconnected from the motor while the winding are reconfigured via
external switching
When a motor is driven by the supply either at full speed or at part speed there is a rotating
magnetic field in the stator This field is rotating at line frequency The flux from the stator field
induces a current in the rotor and this in turn results in a rotor magnetic field
When the motor is disconnected from the supply (open transition) there is a spinning rotor within
the stator and the rotor has a magnetic field Due to the low impedance of the rotor circuit the time
constant is quite long and the action of the spinning rotor field within the stator is that of a
generator which generates voltage at a frequency determined by the speed of the rotor When the
motor is reconnected to the supply it is reclosing onto an unsynchronized generator and this result
in a very high current and torque transient The magnitude of the transient is dependent on the
phase relationship between the generated voltage and the line voltage at the point of closure can
be much higher than DOL current and torque and can result in electrical and mechanical damage
Open transition starting is the easiest to implement in terms or cost and circuitry and if the timing
of the changeover is good this method can work well In practice though it is difficult to set the
necessary timing to operate correctly and disconnectionreconnection of the supply can cause
significant voltagecurrent transients
In Open transition there are Four states
23 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 OFF State All Contactors are open
2 Star State The Main [KM3] and the Star [KM1] contactors are closed and the delta [KM2]
contactor is open The motor is connected in star and will produce one third of DOL torque at one
third of DOL current
3 Open State This type of operation is called open transition switching because there is an
open state between the star state and the delta state The Main contractor is closed and the Delta
and Star contactors are open There is voltage on one end of the motor windings but the other end
is open so no current can flow The motor has a spinning rotor and behaves like a generator
4 Delta State The Main and the Delta contactors are closed The Star contactor is open The
motor is connected to full line voltage and full power and torque are available
(2) Closed Transition StarDelta Starter
There is a technique to reduce the magnitude of the switching transients This requires the use of a
fourth contactor and a set of three resistors The resistors must be sized such that considerable
current is able to flow in the motor windings while they are in circuit
The auxiliary contactor and resistors are connected across the delta contactor In operation just
before the star contactor opens the auxiliary contactor closes resulting in current flow via the
resistors into the star connection Once the star contactor opens current is able to flow round
through the motor windings to the supply via the resistors These resistors are then shorted by the
delta contactor If the resistance of the resistors is too high they will not swamp the voltage
generated by the motor and will serve no purpose
In closed transition the power is maintained to the motor at all time This is achieved by
introducing resistors to take up the current flow during the winding changeover A fourth
contractor is required to place the resistor in circuit before opening the star contactor and then
removing the resistors once the delta contactor is closed These resistors need to be sized to carry
the motor current In addition to requiring more switching devices the control circuit is more
complicated due to the need to carry out resistor switching
In Close transition there are Four states
1 OFF State All Contactors are open
2 Star State The Main [KM3] and the Star [KM1] contactors are closed and the delta [KM2]
contactor is open The motor is connected in star and will produce one third of DOL torque at one
third of DOL current
Star Transition State The motor is connected in star and the resistors are connected across the
delta contactor via the aux [KM4] contactor
24 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Closed Transition State The Main [KM3] contactor is closed and the Delta [KM2] and Star
[KM1] contactors are open Current flows through the motor windings and the transition resistors
via KM4
Delta State The Main and the Delta contactors are closed The transition resistors are shorted out
The Star contactor is open The motor is connected to full line voltage and full power and torque
are available
Effect of Transient in Starter (Open Transient starter)
It is Important the pause between star contactor switch off and Delta contactor switch is on correct
This is because Star contactor must be reliably disconnected before Delta contactor is activated It
is also important that the switch over pause is not too long
For 415v Star Connection voltage is effectively reduced to 58 or 240v The equivalent of 33
that is obtained with Direct Online (DOL) starting
If Star connection has sufficient torque to run up to 75 or 80 of full load speed then the motor
can be connected in Delta mode
When connected to Delta configuration the phase voltage increases by a ratio of V3 or 173 The
phase currents increase by the same ratio The line current increases three times its value in star
connection
During transition period of switchover the motor must be free running with little deceleration
While this is happening ldquoCoastingrdquo it may generate a voltage of its own and on connection to the
supply this voltage can randomly add to or subtract from the applied line voltage This is known as
transient current Only lasting a few milliseconds it causes voltage surges and spikes Known as
a changeover transient
Size of each part of Star-Delta starter
(1) Size of Over Load Relay
For a star-delta starter there is a possibility to place the overload protection in two positions in the
line or in the windings
Overload Relay in Line
In the line is the same as just putting the overload before the motor as with a DOL starter
The rating of Overload (In Line) = FLC of Motor
Disadvantage If the overload is set to FLC then it is not protecting the motor while it is in delta
(setting is x1732 too high)
Overload Relay in Winding
25 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
In the windings means that the overload is placed after the point where the wiring to the contactors
are split into main and delta The overload then always measures the current inside the windings
The setting of Overload Relay (In Winding) =058 X FLC (line current)
Disadvantage We must use separate short circuit and overload protections
(2) Size of Main and Delta Contractor
1 There are two contactors that are close during run often referred to as the main contractor and
the delta contactor These are AC3 rated at 58 of the current rating of the motor
Size of Main Contactor= IFL x 058
(3) Size of Star Contractor
The third contactor is the star contactor and that only carries star current while the motor is
connected in star The current in star is 1 radic3= (58) of the current in delta so this contactor can
be AC3 rated at one third (33) of the motor rating
Size of Star Contactor= IFL x 033
Motor Starting Characteristics of Star-Delta Starter
Available starting current 33 Full Load Current
Peak starting current 13 to 26 Full Load Current
Peak starting torque 33 Full Load Torque
Advantages of Star-Delta starter
The operation of the star-delta method is simple and rugged
It is relatively cheap compared to other reduced voltage methods
Good TorqueCurrent Performance
It draws 2 times starting current of the full load ampere of the motor connected
Disadvantages of Star-Delta starter
Low Starting Torque (Torque = (Square of Voltage) is also reduce)
Break In Supply ndash Possible Transients
Six Terminal Motor Required (Delta Connected)
It requires 2 set of cables from starter to motor
It provides only 33 starting torque and if the load connected to the subject motor requires higher
starting torque at the time of starting than very heavy transients and stresses are produced while
changing from star to delta connections and because of these transients and stresses many
electrical and mechanical break-down occurs
26 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
In this method of starting initially motor is connected in star and then after change over the motor
is connected in delta The delta of motor is formed in starter and not on motor terminals
High transmission and current peaks When starting up pumps and fans for example the load
torque is low at the beginning of the start and increases with the square of the speed When
reaching approx 80-85 of the motor rated speed the load torque is equal to the motor torque and
the acceleration ceases To reach the rated speed a switch over to delta position is necessary and
this will very often result in high transmission and current peaks In some cases the current peak
can reach a value that is even bigger than for a DOL start
Applications with a load torque higher than 50 of the motor rated torque will not be able to start
using the start-delta starter
Low Starting Torque The star-delta (wye-delta) starting method controls whether the lead
connections from the motor are configured in a star or delta electrical connection The initial
connection should be in the star pattern that results in a reduction of the line voltage by a factor of
1radic3 (577) to the motor and the current is reduced to 13 of the current at full voltage but the
starting torque is also reduced 13 to 15 of the DOL starting torque
The transition from star to delta transition usually occurs once nominal speed is reached but is
sometimes performed as low as 50 of nominal speed which make transient Sparks
Features of star-delta starting
1 For low- to high-power three-phase motors
2 Reduced starting current
3 Six connection cables
4 Reduced starting torque
5 Current peak on changeover from star to delta
6 Mechanical load on changeover from star to delta
Application of Star-Delta Starter
The star-delta method is usually only applied to low to medium voltage and light starting
Torque motors
The received starting current is about 30 of the starting current during direct on line start and the
starting torque is reduced to about 25 of the torque available at a DOL start This starting
method only works when the application is light loaded during the start If the motor is too heavily
27 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
loaded there will not be enough torque to accelerate the motor up to speed before switching over
to the delta position
LESSON 1 WIRING SYSTEM OF SINGLE PHASE DISTRIBUTION BOARD
Introduction
28 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
29 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
30 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
31 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 2 WIRING SYSTEM OF SINGLE PHASE LIGHTING CIRCUIT Introduction
Objectives
1 Identify component and the specification
2 Wire component according to the schematic diagram
3 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Wiring bay Perforated metal 180 cm x 180 cm 1
2 Cut out fuse 63 A 240 V 1
3 Neutral link 1
4 Single pole one way switch cw
switch box
5A 240Vac 4
5 single pole two way switch cw
switch box
5A 240Vac 2
6 RCCB In = 40 A Tripping current
100mA240 Vac 50 Hz
1
7 Main switch 32 A 240V 1
8 kWatthour meter 40 A 240 Vac 1
9 Single pole MCB 6A 240 Vac 1
10 Self tapping Wood screw As required
11 DIN rail 35 mm width As required
32 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
12 PVC trunking 50 mm x 50 mm As required
13 Terminal blocks 5 A As required
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
1 One way switch to control one lamp
2 One way switch to control two lamps
3 Two of two way switch to control one lamp
4 Two of single pole two way switch and one of an intermediate switch to control one
lamp
5 One unit of ceiling fan and fan regulator to be controlled by one way switch
4 Test the functionality of completed project
LESSON 3ndash WIRING SYSTEM OF SINGLE PHASE POWER CIRCUIT Introduction
33 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
34 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify types of component and its specification
2 Wire component according to the schematic diagram given
3 Test the functionality of the circuit dead circuit test life circuit test
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board Perforated Metal 1
2 kWh meter 240 V 40 A 1
3 Socket outlet 13A 240Vac 4
4 RCCB 40A Trip Amps
30mA240 Vac
1
5 3 pin socket 240Vac 13A 4
6 Single pole MCB 20A 240 V 2
7 DOL starter 1 kW 240Vac 2
8 1 phase induction motor 2Hp 240 Vac 1
9 Cooker control unit 4kW 240Vac 1
10 Water heater point 4kW 240 Vac 1
11 DIN rail 35 mm As required
12 PVC casing 20mm As required
13 Flexible wires 05 mm As required
14 Terminal block 10 A As required
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Wire two unit of 13 A socket outlet in radial circuit
3 Wire four units of 13 A socket outlet in ring circuit
4 Wire one unit DOL starter for air-conditioner point
5 Wire one unit of cooker control unit point
6 Wire one unit of water heater point
7 Test the functionality of each component by using mmeter or power supply whichever
applicable
8 Wire component according to circuit diagram
9 Test the functionality of completed project dead circuit test life circuit test
Note
35 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Ensure that the correct rating of protection device and size of wire used
LESSON 4ndash CONDUIT BENDING AND TRUNKING FABRICATION TECHNIQUE
Common fitting used in an industrial wiring
Cutting and threading the condute
36 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
37 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
38 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify conduit fitting and the specification
2 Measure and Cut steel conduit according to specified dimension
3 Bend and fabricate conduit at 45 90 according to layout diagram
4 Wire component according to the schematic diagram
5 Test the functionality of the circuit
39 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Conduit Bender Oslash 19 mm ( frac34 ldquo) 1
2 Measuring Tape 3 metre 1
3 Hacksaw frame and blade 30cm 1
4 Conduit cutter 1
5 Pipe Vise 1
6 Pipe Wrench 1
7 Ratchet Dies 20 mm 1
8 Metal trunking 50 mm x 50 mm 1
9 GI conduit 20mm 1
10 End box 20 mm 1
11 Flexible wires 05 mm As required
12 Connectors 5 A As required
13 Single core PVC ins Cable 25 mm 2 As required
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Wire two unit of 13 A socket outlet in radial circuit
3 Wire four unit of 13 A socket outlet in ring circuit
4 Wire one unit DOL starter for air-conditioner point
5 Wire one unit of cooker control unit point
6 Wire one unit of water heater point
7 Test the functionality of each component by using multimeter or power supply whichever
applicable
8 Wire component according to circuit diagram
9 Test the functionality of completed project
Note
Ensure that the rating of protection device and size of wire
K prior to 31 March
2004 (BS 7671)
(formerly)
bare conductor
sleeved at terminations (formerly)
40 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 5 ndashWIRING SYSTEM OF 1 Oslash LIGHTING AND POWER CIRCUIT
POWER CIRCUITSa Radial circuits
Radial circuits are arranged in the same way as item 1 above in lighting layouts in that each socket
outlet is supplied via the previous one
Points to note
1 The number of socket outlets complying with BS 1363 is unlimited for a floor area of up to 50m 2 if
the circuit protection is a 30 A or 32 A cartridge fuse or circuit breaker the cable being 4 mm PVC
copper or 25 mm2 mineral insulated (mi)
2 The number of socket outlets is unlimited for a floor area up to 20 m 2 with any type of circuit
protection of 20 A using 25 mm2 PVC copper cable or 15 mm2 mi
3 The total number of fused spurs is unlimited
b ring final circuits
These circuits are the same as radial circuits except that the final socket outlet is wired back to the
supply position In effect any outlet is supplied from two directions (Fig 152)
Points to note
1 Every twin-socket outlet counts as two single-socket outlets
2 The number of non-fused spurs must not exceed the total number of points on the ring Fig 158
shows seven points on the ring and five spurs
3 The fuse rating of a fused spur box must not exceed 13 A and the current rating of all points supplied
by the fused spur must not exceed 13 A
4 Non-fused spurs must supply no more than one single or one double socket on the ring Fig 158
shows seven points on the ring and five spurs rating of all points supplied by the fused spur must not
exceed 13 A or one stationary appliance
CapacityMain conductor size
copper (mm2)
Earth conductor
size (mm2)
Circuit breaker
capacity (A)
Up to 600 W 15 15 6
600ndash1200 W 1525 15 10
1200ndash1800 W 254 25 16
41 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Ring circuit
(floor area 100 m2)25 15 3032
A2 radial circuit
(floor area 75 m2)40 25 3032
A3 radial circuit
(floor area 50 m2)25 15 20
Air conditioner (15 tonne) 60 60 3032
Cooker 60 60 3032
Water heater 40 40 20
Objectives
1 Identify component and the specification
2 Wire component according to the schematic diagram
3 Test the functionality of the circuit
42 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board Perforated 1
2 Cut out fuse and neutral link 60A 240V 1each
3 kWh meter 240V 40A 1
4 Switched Socket outlet 13A 240Vac 4
5 Single pole two way switch cw switch
box
5A 240Vac 2
6 RCCB ELCB 63 A Tripping current 100mA
415 Vac
1
7 3 pin plug 240Vac 13A 4
8 Single pole MCB 20 A 2
9 Single pole MCB 6A 1
10 Single pole MCB 20A 2
11 DOL starter 240Vac 2
12 1 phase induction motor 2hp 240 Vac 1
13 Self tapping Wood screw As required
14 DIN rail Stainless steel allum35 mm As required
15 PVC pipe 20mm dia As required
16 End box 20 mm dia 4
17 Flexible wires 05 mm 2 As required
18 Connectors 5 A As required
Procedures
43 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
4 Test the functionality of completed project
LESSON 6 ndash WIRING SYSTEM OF 3 Oslash DISTRIBUTION BOARD
Introduction
44 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
45 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
46 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
47 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
48 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify each component and the specification
2 Wire component according to the schematic diagram given
3 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting Board 450 x 600 mm Perforated metal 1
2 5 pin round socket and plug 415V ac 32A 1
3 Cut out fuse 60 A 3
4 Neutral link 1
5 kWatt hour meter 415V 60A 1
6 ELCB RCCB 3P+N In=63A415 Vac I trip= 300mA 1
7 ELCB RCCB 3P+N In=63A415 Vac I trip= 30mA 1
8 Single pole MCB 6A 240 V 3
9 Single pole MCB 20A 240 V 3
10 DOL starter 20 A 240Vac 2
11 Socket outlet 15 A 240 Vac 1
12 Switched Socket outlet 13 A 240 Vac 3
13 Led indicating light 5A 240 Vac 3
14 Single pole 4 gang 1 way switch 5A 240 Vac 2
15 Single pole 2 way switch 5A 240 Vac 2
16 1 phase induction motor 1 kW 240Vac 1
17 Metal trunking 30 mm x30 mm As required
18 Self tapping Wood screw 4 mm x 20 mm As required
19 DIN rail 25 mm x 1mm
20 GI steel rigid conduit 20mm As required
21 Flexible conduit 20mm As required
22 End box 20 mm 4
23 Flexible wires 05 mm 2 As required
24 Single core PVC insulated wire 15 mm 2 As required
25 Single core PVC insulated wires 25 mm 2 As required
26 Terminal block 10 A As required
Procedures
49 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify each components and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
4 Test the functionality of completed project
1 dead circuit test
2 life circuit
Note Proper earthing should be made
50 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 7 ndash WIRING SYSTEM OF THREE PHASE LIGHTING AND POWER CIRCUIT
51 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
52 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify component and the specification
2 Wire component according to the schematic diagram
3 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting bay Board Perforated metal 180 cm x 180 cm 1
2 k Watt hour meter 415V 60A 1
3 MCCB 415V 60A
4 ELCB RCCB In=60A415 Vac I trip=30mA 1
5 5 pin round Socket and
plug
415Vac 32A 4
6 Single pole MCB 6A 1
7 Triple pole MCB 20A 2
8 Triple pole Main switch 60A 1
9 DOL starter 240Vac 2
10 3 phase induction motor 2hp 415 Vac 1
11 1 phase induction motor 1
12 Metal trunking 30 mm x30 mm As required
13 Self tapping Wood screw 4 mm x 20 mm As required
14 DIN rail 25 mm x 1mm
15 GI steel rigid conduit 20mm As required
16 Flexible conduit 20mm As required
17 End box 20 mm 4
18 Flexible wires 05 mm As required
19 Connectors 10 A As required
Procedures
1 Identify each components and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
4 Test the functionality of completed project
1 dead circuit 2 life circuit test
5 Record the current drawn by the load as connected in star and delta
Note Proper earthing should be made
53 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 8 INSPECTION AND TESTING OF ELECTRICAL INSTALLATION
On completion of a wiring installation a number of tests on the installation have to be conducted to
ascertain that the wiring circuits and connected appliances are safe for use Prior to carrying out the
tests an inspection has to be done The results of the inspectionsupervision and test have to be
presented in Form G (as in Appendix IV) and Form H (as in Appendix V)
To have the test certification as in Form H the following tests shall be conducted
i Continuity Test
ii Insulation Resistance Test
iii Polarity Test
iv Earth Electrode Resistance test and
v Residual Current Device Test
1 Continuity Test
There are 3 main types of continuity tests for the final circuits-
i Protection Conductor Continuity Test
ii Final Ring Circuit Conductor Continuity Test
iii Live and Neutral Conductor Continuity Test
a) Protection Conductor Continuity Test
bull To ascertain that all protection conductors are connected in the correct and effective manner
bull Test equipment ndash Multimeter (Ohm range) or Ohm meter
54 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
bull Test Method
1 1048766 Ensure that the main switch RCD and MCB are open circuited (switched off) and all loads
are disconnected
2 1048766 Connected the test leads as in the Figure 81 The meter reading shall be less than 1 Ω
55 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Final Ring Circuit Conductor Continuity Test
bull To ensure that all conductors around the ring circuit have continuity
bull Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
bull Test Method
1 1048766 Disconnect both the supply source live conductors from the MCB the neutral conductor
from the neutral terminals and the earth conductor from the earth terminal in the distribution
fuse box
2 1048766 Connect the test leads as in the Figure 82 (EE)
3 1048766 Repeat the procedure for (L-L) and (N-N)
4 1048766 The meter reading value shall be less than 1 ohm
56 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Live and Neutral Conductor Continuity Test
a To ensure that each conductor in the circuit has continuity
b Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
2 Test Method
1 1048766 Switch off the Main switch RCD and MCB
2 1048766 Disconnect all loads
3 1048766 Switch on all switches in the circuit
4 1048766 Disconnect the fusesfinal circuit breakers and close the circuit
5 1048766 Carry out the test as shown in Figure 83
6 1048766 The meter reading value shall be less than 1Ω
57 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
58 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
CONTINUITY TEST
Insulation Resistance Test
i Ensure that there is no leakage current between phase conductors phase and neutral conductors and
phase conductor and earth
ii Test the strength of the cable insulation
iii Test Equipment ndash Insulation Resistance Tester operating voltage is 250VDC or 500VDC
iv Test Method
1 1048766 Switch off main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
59 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
4 1048766 Carry out test as in the Table below
5 1048766 Meter reading value shall be less than 1 Megaohm
60 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
61 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Insulation resitance test
62 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
INSULATION RESISTANCE TEST BETWEEN CONDUCTORS AND OPPOSITE POLARITY
Polarity Testi Ensure that each fuse or single pole control and protection device is connected only in the phase
conductor
ii Intermediate contact of Edison screw lamp holder is connected to the phase conductor
iii Ensure that phase neutral and earth conductors at socket outlets are connected at the correct
terminals
iv Test Equipment ndash Multimeter (Ohm range) or Ohm meter
v Test Method
1 1048766 Switch off Main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in Figure 85
63 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
5 1048766 Test switches and single phase control devices at the phase conductors
6 1048766 Test socket outlet connection sources
7 1048766 Test Edison screw lamp holder connections
8 1048766 Meter reading value shall be less than 1 Ω
64 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Polarity test
65 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Earth Electrode Resistance Testi To test the earth electrode resistance
ii To ascertain the suitability of the location of the electrode
iii To ensure that the electrode is not buried within the resistance area of another electrode
iv Test equipment ndash Earth Resistance Tester
v Test method -
1 1048766 Terminal rsquoErsquo is connected to the electrode to be tested (green conductor)
2 1048766 Terminal lsquoPrsquo is connected to the potential spike (yellow conductor) at a distance of 10
meters from the earth electrode
3 1048766 Terminal lsquoCrsquo is connected to the current spike (red conductor) at a distance of 20 meters
from the earth electrode
Earth Electrode Resistance Measurement Method (Figure 86)
This test must be repeated at least three times to ensure that the reading is not affected by interacting
earthing regions
i Record the first reading (Z1) Example Z1 = 10 Ω
ii Move the voltage spike to a distance of 6 meters from the original position Record the second
reading (Z2 ) Example Z2 = 10 Ω
iii Move the voltage spike to a distance of 6 meters from the original position Record the third
reading (Z3) Example Z3 = 10 Ω
66 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Residual Current Device Testi Ensure that the residual current device (RCD) trips within the set time on the occurrence of current
leakage to earth
ii Test Equipment ndash RCD Tester RCCB Tester
iii Test Method 1
1 1048766 Use the Trip Test Button
2 1048766 Press the trip button found on the RCD to determine if it trips or otherwise This test would
not be able to determine the sensitivity of the RCD nor the time taken for it to trip
iv Test Method 2
i 1048766 Use a RCD Tester
ii This equipment is equipped with a 13A plug which can be connected to a 13A socket outlet
Select the RCD sensitivity to be the same as the sensitivity of the RCD to be tested to
determine if the RCD can trip The time to trip shall not exceed 40 mS
iii 1048766 Test method ndash
a) Position the selection switch in accordance with the sensitivity of the RCD used
Example 100 mA 01 A
b) Position the operations switch to lsquoNo Triprsquo (frac12 Rated mA = 50) connect the 3 pin plug to
the 13A socket outlet
67 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
c) Switch on the 13A socket outlet ndash ensure that the P-N and P-E lights light up
This shows that the polarity is correct (Note if both the lights as above do not light up the test cannot
be continued)
d) Press the test button ndash the reading shows less than 200 mS and simultaneously the lsquotestrsquo light lights
up and the P-N and P-E lights do not light up At that instant the RCD will not trip
e) Move the selection switch to 180o (+ve wave) ndash repeat steps (d) and (e) Move the operations
switch to lsquoTriprsquo (Rated mA = 100)
g) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200mS
h) Move the selection switch to 0o (-ve wave)
i) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
j) The above test is repeated until a near correct reading is obtained
k) Record the test results
l) Change the operations switch to lsquoFast Triprsquo and press the test button ndash RCD will trip within a
time not exceeding 40 millisecond
m) Repeat a number of times at 0o or 180o
On completion of a wiring installation a number of tests on the installation have to be conducted to
ascertain that the wiring circuits and connected appliances are safe for use Prior to carrying out the
tests an inspection has to be done the following tests shall be conducted
i Continuity Test
ii Insulation Resistance Test
iii Polarity Test
iv Earth Electrode Resistance test and
v Residual Current Device Test
821 Continuity Test
There are 3 main types of continuity tests for the final circuits-
i Protection Conductor Continuity Test
ii Final Ring Circuit Conductor Continuity Test
68 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
iii Live and Neutral Conductor Continuity Test
a) Protection Conductor Continuity Test
bull To ascertain that all protection conductors are connected in the correct and effective manner
bull Test equipment ndash Multimeter (Ohm range) or Ohm meter
bull Test Method
1 1048766 Ensure that the main switch RCD and MCB are open circuited (switched off) and all loads are
disconnected
2 1048766 Connected the test leads as in the Figure 81
3 1048766 The meter reading shall be less than 1 Ω
Final Ring Circuit Conductor Continuity Test
bull To ensure that all conductors around the ring circuit have continuity
bull Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
bull Test Method
1 1048766 Disconnect both the supply source live conductors from the MCB the neutral conductor
from the neutral terminals and the earth conductor from the earth terminal in the distribution
fuse box
2 1048766 Connect the test leads as in the Figure 82 (EE)
3 1048766 Repeat the procedure for (L-L) and (N-N)
4 1048766 The meter reading value shall be less than 1 ohm Figure 82 - Final Ring Circuit Conductor
Continuity Test Ohm Meter
Disconnect both the supply source cables from mcbfuse
Take readings at earth conductors of both sources and note resistance readings
Live and Neutral Conductor Continuity Test
1 To ensure that each conductor in the circuit has continuity
2 Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
3 Test Method
1 1048766 Switch off the Main switch RCD and MCB
2 1048766 Disconnect all loads
3 1048766 Switch on all switches in the circuit
4 1048766 Disconnect the fusesfinal circuit breakers and close the circuit
5 1048766 Carry out the test as shown in Figure 83
6 1048766 The meter reading value shall be less than 1 ohm Figure 83 - Live and Neutral
Conductor Continuity Test Ohm Meter
Insulation Resistance Test
69 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
i Ensure that there is no leakage current between phase conductors phase and neutral conductors and
phase conductor and earth
ii Test the strength of the cable insulation
iii Test Equipment ndash Insulation Resistance Tester Operating voltage is 250VDC or 500VDC
iv Test Method
1 1048766 Switch off main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in the Table below
5 1048766 Meter reading value shall be less than 1 Megaohm
Polarity Test
i Ensure that each fuse or single pole control and protection device is connected only in the phase
conductor
ii Intermediate contact of Edison screw lamp holder is connected to the phase conductor
iii Ensure that phase neutral and earth conductors at socket outlets are connected at the correct
terminals
iv Test Equipment ndash Multimeter (Ohm range) or Ohm meter
v Test Method
1 1048766 Switch off Main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in Figure 85
5 1048766 Test switches and single phase control devices at the phase conductors
6 1048766 Test socket outlet connection sources
7 1048766 Test Edison screw lamp holder connections
8 1048766 Meter reading value shall be less than 1 Ω
Earth Electrode Resistance Test
i To test the earth electrode resistance
70 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
ii To ascertain the suitability of the location of the electrode
iii To ensure that the electrode is not buried within the resistance area of another electrode
iv Test equipment ndash Earth Resistance Tester
v Test method -
1 1048766 Terminal rsquoErsquo is connected to the electrode to be tested (green conductor)
2 1048766 Terminal lsquoPrsquo is connected to the potential spike (yellow conductor) at a distance of 10
meters from the earth electrode
3 1048766 Terminal lsquoCrsquo is connected to the current spike (red conductor) at a distance of 20 meters
from the earth electrode E P C Electrode 10 meter 10 meter
Figure 86 ndash Earth Electrode Resistance Measurement Test Equipment
Earth Electrode Resistance Measurement Method (Figure 86)
This test must be repeated at least three times to ensure that the reading is not affected by interacting
earthing regions
i Record the first reading (Z1) Example Z1 = 10 Ω
ii Move the voltage spike to a distance of 6 meters from the original position Record the second
reading (Z2) Example Z2 = 10 Ω
iii Move the voltage spike to a distance of 6 meters from the original position Record the third
reading (Z3)
Example Z3 = 10 Ω
Residual Current Device Test
71 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
i Ensure that the residual current device (RCD) trips within the set time on the occurrence of current
leakage to earth
ii Test Equipment ndash RCD Tester RCCB Tester
iii Test Method 1
1 1048766 Use the Trip Test Button
2 1048766 Press the trip button found on the RCD to determine if it trips or otherwise This test would
not be able to determine the sensitivity of the RCD nor the time taken for it to trip
iv Test Method 2
1048766 Use a RCD Tester
This equipment is equipped with a 13A plug which can be connected to a 13A socket outlet Select the
RCD sensitivity to be the same as the sensitivity of the RCD to be tested to determine if the RCD can
trip The time to trip shall not exceed 40 mS
1048766 Test method ndash
a) Position the selection switch in accordance with the sensitivity of the RCD used
Example 100 mA 01 A
b) Position the operations switch to lsquoNo Triprsquo (frac12 Rated mA = 50) connect the 3 pin plug to
the 13A socket outlet
c) Switch on the 13A socket outlet ndash ensure that the P-N and P-E lights light up This shows that
the polarity is correct (Note if both the lights as above do not light up the test cannot be
continued)
d) Press the test button ndash the reading shows less than 200 millisecond and simultaneously the
lsquotestrsquo light lights up and the P-N and P-E lights do not light up At that instant the RCD will
not trip
e) Move the selection switch to 180o (+ve wave) ndash repeat steps (d) and (e) = 100)
f) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
g) Move the selection switch to 0o (-ve wave)
h) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
i) The above test is repeated until a near correct reading is obtained
j) Record the test results
k) Change the operations switch to lsquoFast Triprsquo and press the test button ndash RCD will trip within a
time not exceeding 40 mS
l) Repeat a number of times at 0o or 180o
72 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 9 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (DC)
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
73 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Start stop button 240Vac 5A 2
9 Filament lamp (Bulb ) 240Vac 40W 3
10 Overload Relay 415V 20A 3
11 Three phase induction motor 5 hp 3
12 Single phase step down transformer 2500VA 1
13 Single core PVC insulated Cable 1mm 2 As required
14 Single core PVC insulated Cable 25mm 2 As required
15 DIN rail 35 mm As required
16 PVC type Cable tray 50 mm x 50 mm As required
17 Cable ties 4 ldquo As required
18 Flexible wires 05 mm As required
19 PVC Connectors 5 A amp 20 A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the schematic
diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a optional exercise
i Simple DOL starter
ii Forward reverse DOL starter
iii Forward Reverse Dahlander motor
iv Three motors operated in sequence by DOL starter operated by manual push
button or time delay relay
74 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
a One loop per-cycle
b Continuous operation in a loop
c optional circuit design to represent the same task
v Only one out of three motors to be operated at a time (quiz)
4 Test the functionality of completed project
LESSON 10 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (AC)
75 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 1
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Lamp point 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
76 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
11 Overload Relay 415V 20A 3
12 Three phase induction
motor
5 hp 3
13 Single core PVC insulated
Cable
1mm 2 As required
14 Single core PVC insulated
Cable
25mm 2 As required
15 DIN rail 35 mm As required
16 PVC type Cable tray 50 mm x 50 mm As required
17 Cable ties 4 ldquo As required
18 Flexible wires 05 mm As required
19 PVC Connectors 5 A amp 20 A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the
schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram optional exercise
4 Simple DOL starter
5 Forward reverse DOL starter
6 Test the functionality of completed project
77 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 1
78 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
cm
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Indicating light 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
11 Overload Relay 415V 20A 3
12 Three phase induction motor 5 hp 3
13 Single phase step down
transformer
2500VA 1
14 Single core PVC insulated
Cable
1mm 2 As required
15 Single core PVC insulated
Cable
25mm 2 As required
16 DIN rail 35 mm As required
17 PVC type Cable tray 50 mm x 50 mm As required
18 Cable ties 4 ldquo As required
19 Flexible wires 05 mm As required
20 PVC Connectors 5 A amp 20 A 240 V As required
21 Single pole MCB 6A 240 V 1
22 Single pole MCB 2A 240 V 1
23 Triple pole MCB 20A 415 V 1
24 Mounting board 30 cm x 40 cm x 3
cm
1
25 Relay cw 11 pin socket 10 A 240 Vac 2
26 Time delay relay 10 A 240 Vac 3
27 Triple pole Contactor 20A 240Vac 3
28 Batten type Lamp holder 240Vac 10 A 3
29 Start stop button 240Vac 10A 2
30 Indicating light (Bulb ) 240Vac 25W 3
31 Overload Relay 415V 20A 1
32 Three phase dahlander type
induction motor
5 hp 1
33 Single phase step down
transformer
24024Vac
2500VA
1
79 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
34 Single core PVC insulated
Cable
1mm 2 As required
35 Single core PVC insulated
Cable
25mm 2 As required
36 DIN rail 35 mm As required
37 PVC type Cable tray 50 mm x 50 mm As required
38 Cable ties 4 ldquo As required
39 Flexible wires 075 mm As required
40 PVC Connectors 5 A amp 20 A 240 V As required
41 Terminal block 20A 240Vac As required
Procedures
5 Identify each component according to specification and quantity required from the schematic
diagram attached
6 Test the functionality of each component by using multi-meter or power supply whichever
applicable
7 Wire component according to circuit diagram
8 Three motors operated in sequence by DOL starter operated by manual push button or time
delay relay
a One loop per-cycle
b Continuous operation in a loop
c optional circuit design to represent the same task
d Only one out of three motors to be operated at a time (quiz)
9 Test the functionality of completed project
80 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
BASIC DESIGN INDUSTRIAL MOTOR CONTROL (SEQUENCE CONTROL)
THREE PHASE INDUCTION MOTOR OPERATED IN SEQUENCE BY DIRECT ON LINE
STARTER
LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
81 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
82 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Lcd lamp indicator 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
11 Overload Relay 415V 20A 3
12 Three phase induction motor 5 hp 3
13 Single phase step down transformer 2500VA 1
14 Single core PVC insulated Cable 1mm 2 As required
15 Single core PVC insulated Cable 25mm 2 As required
16 DIN rail 35 mm As required
17 PVC type Cable tray 50 mm x 50 mm As required
18 Cable ties 4 ldquo As required
19 Flexible wires 1 mm Oslash As required
20 PVC Terminal block 10A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the schematic
diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a optional exercise
i Forward Reverse dahlander motor
4 Test the functionality of completed project
83 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
THREE PHASE DAHLANDER TYPE INDUCTION MOTOR OPERATED FORWARD AND
REVERSE OPERATION BY DIRECT ON LINE STARTER
84 ndash 99EASYTECH ENTERPRISE
LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
Introduction
If a motors windings are connected in the star configuration any two phases will be in series across
the supply and hence the line current will be smaller(by 577) than if the windings were connected in
the delta arrangement
Hence larger-type motors with heavy starting currents are first connected in star and then when the
starting currents fall in delta This of course means that all six of the ends of the windings must be
brought to terminations outside the casing (Fig 833)
EZTECH
EZTECH ELECTRICAL INSTALLATION GUIDE
The automatic version of this starter incorporates a timing relay which automatically changes the
connections from star to delta Figs 834 and 835 show the wiring and schematic diagrams for a star
delta starter
Objectives
1 Identify component and the specification
2 Design forward reverse star delta starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
2 ndash 99EASYTECH ENTERPRISE
REV -C
LEGENDMCCB Moulded Case Circuit BreakerTOR Thermal Over Load RelayFOW-C Mains Forward ContactorREV-C Mains Reverse ContactorDC Delta ContactorSC Star ContactorS-SW Mains Selector Switch
SC
V2
W2
U2
DC
V1
W1
U1
TOR
TOR
FOW-C
30A MCCB
TOR
MAIN CIRCUIT FORWARD REVERSE STAR DELTA
RYBN S
-SW
3 PHASEINDUCTION MOTOR
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Relay 10 A 240V 3
5 Triple pole Contactor
6 cw NO NC auxiliary contact
240Vac 20 A 4
7 Overload Relay 415 V 1
8 LED indicator 240vac 5 A 4
9 Start stop button 240Vac 5A 2
10 DIN rail 35 mm As required
11 Flexible wires 1 mm As required
12 Single core PVC insulated
wire
25 mm As required
13 Terminal block 20 A As required
14 Squirrel cage motor 5kW 1
15 5 pin plug and socket 415V 20A 1
16 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
3 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
a Manual star delta
b Manual Forward reverse star delta starter
c Automatic star delta starter
d Automatic Forward reverse star delta starter
4 Test the functionality of completed project
4 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
Objectives
1 Identify component and the specification
2 Design auto transformer starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
5 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Autotransformer starter is used to start a 3 phase induction motor that has a rating between 10 to 15 hp
6 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Autotransformer set 10Kw 415 V 50 Hz 1
5 Triple pole Contactor 240Vac 4
6 Batten type Lamp holder 240 Vac 105 A 4
7 Start stop button 240Vac 10A 4
8 Filament lamp (Bulb ) 240Vac 40W 4
9 DIN rail 35 mm As required
10 Flexible wires 1 mm As required
7 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
11 Single core PVC insulated
wire
25 mm As required
12 Terminal block 20 A As required
13 Squirrel cage motor 10kW 1
14 5 pin plug and socket 415V 20A 1
15 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a open transient autotransformer starter
b close transient autotransformer starter
c Forward reverse autotransformer starter
4 Test the functionality of completed project
8 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
Objectives
1 Identify component and the specification
2 Design rotor resistance starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
9 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Rotor Resistor set 10kW 1
5 Triple pole Contactor 240Vac 20A 4
6 Indicating light 240vac 5 A 4
7 Start stop push button 240Vac 5A 4
8 DIN rail 35 mm As required
9 Flexible wires 1 mm 2 As required
10 Single core PVC insulated wire 25 mm 2 As required
11 Terminal block 20 A As required
12 Slip Ring motor 10kW 1
13 5 pin round 3 phase socket 415V 20A 1
14 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
10 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
4 Test the functionality of completed project
a Dead circuit test b Life circuit test
5 Measure starting and running Amps
LESSON 16
TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
An installation in general will suffer damage
Damage usually occurs on the electric motor control as follows
1 Damage to the main circuit
2 Damage to the control circuit
The cause of the damage
i Overcurrent overload short circuit
ii Leakage current to ground
iii Equipment malfunction
iv The main control circuit
a Trip of main circuit protection devices fire
b Defect of motor terminal such as short circuit fire loose
v The control circuit is not functioning -
a contactor relay relay time overload relay does not work damaged burned
b Loose cable connection disconnected
Detecting and Repairing Damage
Examples of damage are as follows
i Motor does not work
ii Motor function and overload relay trips
iii Motor function but only partially functional control circuit
Methods of detecting damage
Among the known methods necessary to detect damage are as follows
1 Turn off the electricity at the main switch (main switch) in order to avoid any danger during the
work carried out to detect damage
2 Check all the protective gear that controls the motor control main circuit
11 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
3 Make sure the damage function control circuit
4 Check the control circuit according to the schematic circuit diagram of the motor control
5 Check the operation of the control circuit
Note
Use wiring that has been installed on the SYSTEM OF MOTOR CONTROL BOARD by Forward
Reverse control circuit for Star Delta to test and look for damage
SELF-ASSESSMENT QUESTIONS
1 (a) Explain what is meant by the term lsquoback emfrsquo in a motor
(b) Outline the basic differences between series shunt and compound wound dc motors
2 (a) With the aid of diagrams explain how the speed of series shunt and compound-wound motors
may be controlled
(b) A 440V dc shunt-wound motor has a field resistance of 200R and an armature resistance of 06 R
When its speed is 20 rev d second the current drawn from the supply is 122A Calculate its back
emf at this speed If the speed were decreased to 19 revssecond the field flux remaining unchanged
calculate the new back emf and the new armature current
3 A load of 64 kW at 240 V is supplied from the terminals of a shunt-wound dc generator The field
resistance is 180 A Calculate the armature current
4 (a) Explain with the aid of a diagram how a rotating magnetic field may be
(b) What is meant by lsquosynchronous speedrsquo
Calculate the synchronous obtained speed of a 12 pole motor if the supply frequency is 50Hz
5 (a) Explain the action of a synchronous motor
(b) What methods are available to start a synchronous motor Explain with diagrams
6 (a) Explain the action of a cage induction motor
(b) What is meant by the term lsquosliprsquo
Calculate the percentage slip of a six pole induction motor running at 162 revssecond from a 50 Hz
supply
7 Describe with sketches three different ways of starting a single-phase induction motor
12 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
8 Explain with the aid of a sketch the action of a three-phase DOL starter
What are dashpots used for How are remote start and stop buttons connected
9 A I0 kW 240V 50Hz single-phase cage rotor induction motor is 85efficient and has a PF of 068
lagging Calculate the motor current and the value of capacitor required to raise the PF to 093
lagging
10 Calculate the torque developed by an 18 kW four-pole induction motor run at 35 slip from a
50Hz supply
APPENDIX 1
13 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 11
14 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 111
Attachment Reference
httpswwwtlc-directcoukBook621htm
httpwwwstgovmyindexphpms
15 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
The motor starter shall be of Direct-On-Line type with the appliance together with the contactor
overload relay and on-off control The circuit breakerfuse which controls the motor circuit shall be
capable of withstanding the starting current of the motor
x Electric bells ndash the circuit shall have a push button switch and a ACDC transformer
xi Ceiling fans shall conform to clause 21101 of the MS 12192002 standard with regards to test on
the suspension system of ceiling fans
EARTHING OF ELECTRICAL INSTALLATIONS51 Earthing
Earthing is a connection system between the metallic parts of an electrical wiring system and the
general mass of the earth This will provide an easy path with a low impedence or resistance to earth to
enable the protection system to operate effectively It will thus ensure safety to human
beingsconsumers from the dangers of electric shocks if earth leakage currents are present In general
an electrical installation is earthed because of -
i Safety reasons
ii Protection system requirements
iii Need to limit over voltages
iv Need to provide a path for electrical discharge
v Legal requirements
52 Classification of Earthing
Generally earthing can be divided into 2 parts namely -
i System Earthing
a To isolate the system under fault conditions
b To limit the potential difference between conductors which are not insulated in an area
c To limit the occurrence of over voltages under various conditions
ii Equipment Earthing
Equipment earthing is undertaken to protect human beingsconsumers If a live source comes into
contact with the equipment body electrical energy will flow to the earth without flowing through the
human being consumerrsquos body This is because of the fact that the human body has a greater
resistance compared with the resistance to earth
53 Types and Functions of Earthing Accessories
Earthing accessories are as follows -
i Earthing Electrode
Copper jacketed steel core rods are used as electrodes for domestic wiring
ii Equipotential Bonding
15 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
This is the conductor which is connected between the consumer earthing point and the exposed
metallic part The minimum cable size for this purpose is 10 mm2
iii Protection Conductor
This is the conductor which connects the consumer earthing point with other parts of the installation
which needs earthing Its size is as follows-
a) Same size as the phase cable up to a size of 16mm2
b) 16 mm2 if the phase cable size is between 16 mm2 and 35 mm2
c) Half the size of the phase cable if the size of the phase cable exceeds 35 mm2
54 Earthing Arrangements Using a TT System
i The first alphabet indicates the earthing arrangements from the supply side
ii The second alphabet indicates the earthing arrangement in the consumerrsquos installation
T ndash first Indicates that the supply system has its own earthing arrangements
T ndash second Indicates that all metallic frames of the electrical appliances etc are connected directly to
earth
Parts that are Required to be Earthed
i All metallic structures in the wiring system (non current carrying) such as metallic covers conduits
ducts the armour of catenary wires etc
ii A secondary winding point in a transformer and
iii Frame of metal roof truss
56 Parts that are not Required to be Earthed
i Short isolated metallic parts for mechanical protection of cables which have non metallic sheaths
other than conduits which are connected at entry points between the building and conduits which
protect discharge lamp cables
ii Cable clips for installing cables
iii Metallic covers for lamps
16 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
iv Small metallic parts such as screws and name plates which are isolated by means of insulation
v Metallic lamp parts for filament lamps in water proof floors
57 Termination to Earth
The termination to earth is done as shown in Figure 72
Earth Electrode Resistance
The maximum permitted earth electrode resistance for different types of installations is as shown in
the Table below
Earth electrode for installations protected by RCDs of sensitivity 100mA 10 Ω
Lightning arrestor earth electrode 10 Ω
Legal Requirements
i Sub regulation 12(1) and 12(2) of the Electricity Regulations 1994 state that any electrical wiring in
an installation shall be under the immediate supervision of a Wireman with Single Phase Restriction or
Three Phase Restriction Upon completion the Wireman shall certify a Supervision and Completion
Certificate
ii Sub regulation 13(1) and 13 (2) of the Electricity Regulations 1994 state that the installation shall
be tested by a Wireman with Single Phase Restriction or a Wireman with Three Phase Restriction
authorized to test any installation and who shall certify a Test Certificate for the installation
iii Sub regulation 14(1) of the Electricity Regulations 1994 states that the Supervision and
Completion Certificate and the Test Certificate as in regulations 12 and 13 shall be in Forms G and H
respectively as prescribed in the First Schedule
17 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
4 SAFETY REQUIREMENTS FOR ELECTRICAL WIRING WORKS IN RESIDENTIAL BUILDINGS
61 Safety Requirements
Safety requirements for electrical wiring works have to be followed to eliminate any accidents which
can result in physical damage or loss of life or property Failure to meet the safety regulations may
result in workers consumers or the public being inflicted with electrical shocks
In addition to this safety steps will also encourage workers or electricity consumers who are
disciplined and who always give importance to safety
62 Safety Steps
Safety requirements have to be followed whenever electrical works are undertaken in a residential
building
i Personal Safety
a Use suitable personal protection equipment as needed such as safety shoes gloves safety helmet
etc when at the work place
b Use safety clothing suitable for the work to be undertaken
c Do not wear jewellery or decorative items such as rings watches chains etc while carrying out
electrical works
ii Safety at the Work Place
a Acquire knowledge about the dangers of electrical works that is to be undertaken and how to deal
with those dangers
b Always adhere to the safety regulations which have been set for the work place
c Ensure that the electricity supply is switched off before carrying out the works
d Acquire the needed knowledge and practice a cautious and calm attitude while working ensure
cleanliness in and around fellow workers
e While working at elevated places the worker should always use suitable equipment such as wooden
or aluminium ladders iron scaffoldings or platforms safety belts or other equipment needed to ensure
that the work can be undertaken safely
f Use electrical equipment which is operational and safe to be used and ensure that the supply for it is
being supplied through a residual current device (RCD) with a sensitivity of 30 mA
g Ensure that exposed temporary supply electrical cables have mechanical protection
h If inflammable or corrosive material is present necessary safety steps have to be undertaken as
required by the relevant safety regulations
63 Dangers of Electrical Shocks
i Electrical Shock
Electrical shocks can occur due to direct or indirect contact
a Direct Contact
18 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Direct contact occurs when the worker or consumer receives an electrical shock on touching directly a
live conductor or cable
b Indirect Contact
Here the electric shock occurs due to contact with a part which is connected to the electrical
installation and not to a direct contact with a live cable or conductor possibly due to damages in the
appliance or insulation resulting in leakages of current
Why Electric Shocks Occura Unsafe Work Method or Action Undertaking Electrical Work Without Disconnecting the
Supply
Maintenance or circuit testing work done without disconnecting the supply will have a high possibility
of electrical shocks occurring
bull Not Following Safe Work Procedures
To eliminate the occurrence of electrical shocks each worker has to always follow safe work
procedures which are set by regulations and standards
b Defects in the Electrical System
i Leakage Current
Leakage currents or earth leakage currents can result in the metallic frames becoming live and
energised This can give rise to the danger of electrical shock to the worker consumer or the public if
they hold or come into contact with the metallic frame
ii Exposed Conductor or Disconnected Cable
Exposed conductors or cables which are broken and are alive (energised) can result in electrical shock
when touched The supply source must be immediately isolated or switched off and a report must be
made to the responsible entity
64 First Aid and Basic Pulmonary Resuscitation
i First Aid
First aid is the initial assistance given to a person who has met with an accident is sick or is injured to
prevent the condition of the victim from becoming more serious while awaiting the arrival of the
paramedics (ambulance) or before being brought to the hospital
i Pulmonary Resuscitation
Pulmonary resuscitation has to be undertaken to assist the victim who has breathing difficulties as a
result of being drowned receiving an electrical shock etc Pulmonary resuscitation has to be carried
out in accordance to the correct method as stated in the first aid manuals issued by accredited first aid
bodies
ii First Aid Box
19 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
A first aid box has to be provided by the building owner construction site supervisor or brought
personally by the worker under the supervision of the responsible person
65 Training Programme
The management shall conduct periodic training programmes for the workers with regards to work
safety on aspects including the following -
i Dangers of electrical work being undertaken and how to control those dangers
ii The safety regulations set for the work place and
iii First aid procedures
66 Fire Prevention
Fire Extinguisher A suitable functioning fire extinguisher to control fires has to be made available at
the work place at all times
67 Competent Person
The Electricity Regulations 1994 require that all electrical work has to be undertaken by or under the
direct supervision of a competent person registered with the Energy Commission Besides that the
electrical contractor undertaking the electrical work has also to be registered with the Energy
Commission The installation owner thus has to ensure that the appointed electrical contractor is
registered with the Energy Commission and that the registration is still valid
INSTALLATION CIRCUITS AND SYSTEMS1 Block diagrams
These show using squares rectangles etc the sequence of a system without too much technical detail
eg Figures 1517 and 1526
2 Layout diagrams
These are very similar to block diagrams but they indicate more technical detail and tend to show
items in their correct geographical location (eg Figures 1518 and 1519)
3 Circuitschematic
These show how a circuit functions and takes no account of exact locations of terminals or equipment
(eg Figures 1528 1529 1532 1534 etc)
4 Wiring diagram
These indicate how a circuit or system is physically wired (eg Figures 152 154 156 etc)
Most induction motors are started directly on line but when very large motors are started that way
they cause a disturbance of voltage on the supply lines due to large starting current surges To limit the
starting current surge large induction motors are started at reduced voltage and then have full supply
voltage reconnected when they run up to near rotated speed Two methods are used for reduction of
starting voltage are star delta starting and auto transformer stating
20 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Working Principal of Star-Delta Starter
This is the reduced voltage starting method Voltage reduction during star-delta starting is achieved by
physically reconfiguring the motor windings as illustrated in the figure below During starting the
motor windings are connected in star configuration and this reduces the voltage across each winding 3
This also reduces the torque by a factor of three After a period of time the winding are reconfigured as
delta and the motor runs normally
StarDelta starters are probably the most common reduced voltage starters They are used in
an attempt to reduce the start current applied to the motor during start as a means of reducing the
disturbances and interference on the electrical supply
Traditionally in many supply regions there has been a requirement to fit a reduced voltage
starter on all motors greater than 5HP (4KW) The StarDelta (or WyeDelta) starter is one of the
lowest cost electromechanical reduced voltage starters that can be applied
The StarDelta starter is manufactured from three contactors a timer and a thermal overload
The contactors are smaller than the single contactor used in a Direct on Line starter as they are
controlling winding currents only The currents through the winding are 1root 3 (58) of the
current in the line
There are two contactors that are close during run often referred to as the main contractor and
the delta contactor These are AC3 rated at 58 of the current rating of the motor The third
contactor is the star contactor and that only carries star current while the motor is connected in star
The current in star is one third of the current in delta so this contactor can be AC3 rated at one
third (33) of the motor rating
Star-delta Starter Consists following units
1) Contactors (Main star and delta contactors) 3 Norsquos (For Open State Starter) or 4 Norsquos (Close
Transient Starter)
2) Time relay (pull-in delayed) 1 No
3) Three-pole thermal over current release 1No
4) Fuse elements or automatic cut-outs for the main circuit 3 Nos
5) Fuse element or automatic cut-out for the control circuit 1No
Power Circuit of Star Delta Starter
1 The main circuit breaker serves as the main power supply switch that supplies electricity to the
power circuit
2 The main contactor connects the reference source voltage R Y B to the primary terminal of the
motor U1 V1 W1
21 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
3 In operation the Main Contactor (KM3) and the Star Contactor (KM1) are closed initially and
then after a period of time the star contactor is opened and then the delta contactor (KM2) is
closed The control of the contactors is by the timer (K1T) built into the starter The Star and Delta
are electrically interlocked and preferably mechanically interlocked as well In effect there are
four states
4 The star contactor serves to initially short the secondary terminal of the motor U2 V2 W2 for the
start sequence during the initial run of the motor from standstill This provides one third of DOL
current to the motor thus reducing the high inrush current inherent with large capacity motors at
startup
5 Controlling the interchanging star connection and delta connection of an AC induction motor is
achieved by means of a star delta or wye delta control circuit The control circuit consists of push
button switches auxiliary contacts and a timer
Control Circuit of Star-Delta Starter (Open Transition)
1 The ON push button starts the circuit by initially energizing Star Contactor Coil (KM1) of star
circuit and Timer Coil (KT) circuit
2 When Star Contactor Coil (KM1) energized Star Main and Auxiliary contactor change its
position from NO to NC
3 When Star Auxiliary Contactor (1)( which is placed on Main Contactor coil circuit )became
NO to NC itrsquos complete The Circuit of Main contactor Coil (KM3) so Main Contactor Coil
energized and Main Contactorrsquos Main and Auxiliary Contactor Change its Position from NO
To NC This sequence happens in a friction of time
4 After pushing the ON push button switch the auxiliary contact of the main contactor coil (2)
which is connected in parallel across the ON push button will become NO to NC thereby
providing a latch to hold the main contactor coil activated which eventually maintains the
control circuit active even after releasing the ON push button switch
5 When Star Main Contactor (KM1) close its connect Motor connects on STAR and itrsquos
connected in STAR until Time Delay Auxiliary contact KT (3) become NC to NO
6 Once the time delay is reached its specified Time the timerrsquos auxiliary contacts (KT)(3) in
Star Coil circuit will change its position from NC to NO and at the Same Time Auxiliary
contactor (KT) in Delta Coil Circuit(4) change its Position from NO To NC so Delta coil
energized and Delta Main Contactor becomes NO To NC Now Motor terminal connection
change from star to delta connection
7 A normally close auxiliary contact from both star and delta contactors (5amp6)are also placed
opposite of both star and delta contactor coils these interlock contacts serves as safety
switches to prevent simultaneous activation of both star and delta contactor coils so that one
22 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
cannot be activated without the other deactivated first Thus the delta contactor coil cannot be
active when the star contactor coil is active and similarly the star contactor coil cannot also
be active while the delta contactor coil is active
8 The control circuit above also provides two interrupting contacts to shutdown the motor
The OFF push button switch break the control circuit and the motor when necessary The
thermal overload contact is a protective device which automatically opens the STOP Control
circuit in case when motor overload current is detected by the thermal overload relay this is to
prevent burning of the motor in case of excessive load beyond the rated capacity of the motor
is detected by the thermal overload relay
9 At some point during starting it is necessary to change from a star connected winding to a
delta connected winding Power and control circuits can be arranged to this in one of two
ways ndash open transition or closed transition
What is Open or Closed Transition Starting
(1) Open Transition Starters
Discuss mention above is called open transition switching because there is an open state between
the star state and the delta state
In open transition the power is disconnected from the motor while the winding are reconfigured via
external switching
When a motor is driven by the supply either at full speed or at part speed there is a rotating
magnetic field in the stator This field is rotating at line frequency The flux from the stator field
induces a current in the rotor and this in turn results in a rotor magnetic field
When the motor is disconnected from the supply (open transition) there is a spinning rotor within
the stator and the rotor has a magnetic field Due to the low impedance of the rotor circuit the time
constant is quite long and the action of the spinning rotor field within the stator is that of a
generator which generates voltage at a frequency determined by the speed of the rotor When the
motor is reconnected to the supply it is reclosing onto an unsynchronized generator and this result
in a very high current and torque transient The magnitude of the transient is dependent on the
phase relationship between the generated voltage and the line voltage at the point of closure can
be much higher than DOL current and torque and can result in electrical and mechanical damage
Open transition starting is the easiest to implement in terms or cost and circuitry and if the timing
of the changeover is good this method can work well In practice though it is difficult to set the
necessary timing to operate correctly and disconnectionreconnection of the supply can cause
significant voltagecurrent transients
In Open transition there are Four states
23 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 OFF State All Contactors are open
2 Star State The Main [KM3] and the Star [KM1] contactors are closed and the delta [KM2]
contactor is open The motor is connected in star and will produce one third of DOL torque at one
third of DOL current
3 Open State This type of operation is called open transition switching because there is an
open state between the star state and the delta state The Main contractor is closed and the Delta
and Star contactors are open There is voltage on one end of the motor windings but the other end
is open so no current can flow The motor has a spinning rotor and behaves like a generator
4 Delta State The Main and the Delta contactors are closed The Star contactor is open The
motor is connected to full line voltage and full power and torque are available
(2) Closed Transition StarDelta Starter
There is a technique to reduce the magnitude of the switching transients This requires the use of a
fourth contactor and a set of three resistors The resistors must be sized such that considerable
current is able to flow in the motor windings while they are in circuit
The auxiliary contactor and resistors are connected across the delta contactor In operation just
before the star contactor opens the auxiliary contactor closes resulting in current flow via the
resistors into the star connection Once the star contactor opens current is able to flow round
through the motor windings to the supply via the resistors These resistors are then shorted by the
delta contactor If the resistance of the resistors is too high they will not swamp the voltage
generated by the motor and will serve no purpose
In closed transition the power is maintained to the motor at all time This is achieved by
introducing resistors to take up the current flow during the winding changeover A fourth
contractor is required to place the resistor in circuit before opening the star contactor and then
removing the resistors once the delta contactor is closed These resistors need to be sized to carry
the motor current In addition to requiring more switching devices the control circuit is more
complicated due to the need to carry out resistor switching
In Close transition there are Four states
1 OFF State All Contactors are open
2 Star State The Main [KM3] and the Star [KM1] contactors are closed and the delta [KM2]
contactor is open The motor is connected in star and will produce one third of DOL torque at one
third of DOL current
Star Transition State The motor is connected in star and the resistors are connected across the
delta contactor via the aux [KM4] contactor
24 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Closed Transition State The Main [KM3] contactor is closed and the Delta [KM2] and Star
[KM1] contactors are open Current flows through the motor windings and the transition resistors
via KM4
Delta State The Main and the Delta contactors are closed The transition resistors are shorted out
The Star contactor is open The motor is connected to full line voltage and full power and torque
are available
Effect of Transient in Starter (Open Transient starter)
It is Important the pause between star contactor switch off and Delta contactor switch is on correct
This is because Star contactor must be reliably disconnected before Delta contactor is activated It
is also important that the switch over pause is not too long
For 415v Star Connection voltage is effectively reduced to 58 or 240v The equivalent of 33
that is obtained with Direct Online (DOL) starting
If Star connection has sufficient torque to run up to 75 or 80 of full load speed then the motor
can be connected in Delta mode
When connected to Delta configuration the phase voltage increases by a ratio of V3 or 173 The
phase currents increase by the same ratio The line current increases three times its value in star
connection
During transition period of switchover the motor must be free running with little deceleration
While this is happening ldquoCoastingrdquo it may generate a voltage of its own and on connection to the
supply this voltage can randomly add to or subtract from the applied line voltage This is known as
transient current Only lasting a few milliseconds it causes voltage surges and spikes Known as
a changeover transient
Size of each part of Star-Delta starter
(1) Size of Over Load Relay
For a star-delta starter there is a possibility to place the overload protection in two positions in the
line or in the windings
Overload Relay in Line
In the line is the same as just putting the overload before the motor as with a DOL starter
The rating of Overload (In Line) = FLC of Motor
Disadvantage If the overload is set to FLC then it is not protecting the motor while it is in delta
(setting is x1732 too high)
Overload Relay in Winding
25 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
In the windings means that the overload is placed after the point where the wiring to the contactors
are split into main and delta The overload then always measures the current inside the windings
The setting of Overload Relay (In Winding) =058 X FLC (line current)
Disadvantage We must use separate short circuit and overload protections
(2) Size of Main and Delta Contractor
1 There are two contactors that are close during run often referred to as the main contractor and
the delta contactor These are AC3 rated at 58 of the current rating of the motor
Size of Main Contactor= IFL x 058
(3) Size of Star Contractor
The third contactor is the star contactor and that only carries star current while the motor is
connected in star The current in star is 1 radic3= (58) of the current in delta so this contactor can
be AC3 rated at one third (33) of the motor rating
Size of Star Contactor= IFL x 033
Motor Starting Characteristics of Star-Delta Starter
Available starting current 33 Full Load Current
Peak starting current 13 to 26 Full Load Current
Peak starting torque 33 Full Load Torque
Advantages of Star-Delta starter
The operation of the star-delta method is simple and rugged
It is relatively cheap compared to other reduced voltage methods
Good TorqueCurrent Performance
It draws 2 times starting current of the full load ampere of the motor connected
Disadvantages of Star-Delta starter
Low Starting Torque (Torque = (Square of Voltage) is also reduce)
Break In Supply ndash Possible Transients
Six Terminal Motor Required (Delta Connected)
It requires 2 set of cables from starter to motor
It provides only 33 starting torque and if the load connected to the subject motor requires higher
starting torque at the time of starting than very heavy transients and stresses are produced while
changing from star to delta connections and because of these transients and stresses many
electrical and mechanical break-down occurs
26 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
In this method of starting initially motor is connected in star and then after change over the motor
is connected in delta The delta of motor is formed in starter and not on motor terminals
High transmission and current peaks When starting up pumps and fans for example the load
torque is low at the beginning of the start and increases with the square of the speed When
reaching approx 80-85 of the motor rated speed the load torque is equal to the motor torque and
the acceleration ceases To reach the rated speed a switch over to delta position is necessary and
this will very often result in high transmission and current peaks In some cases the current peak
can reach a value that is even bigger than for a DOL start
Applications with a load torque higher than 50 of the motor rated torque will not be able to start
using the start-delta starter
Low Starting Torque The star-delta (wye-delta) starting method controls whether the lead
connections from the motor are configured in a star or delta electrical connection The initial
connection should be in the star pattern that results in a reduction of the line voltage by a factor of
1radic3 (577) to the motor and the current is reduced to 13 of the current at full voltage but the
starting torque is also reduced 13 to 15 of the DOL starting torque
The transition from star to delta transition usually occurs once nominal speed is reached but is
sometimes performed as low as 50 of nominal speed which make transient Sparks
Features of star-delta starting
1 For low- to high-power three-phase motors
2 Reduced starting current
3 Six connection cables
4 Reduced starting torque
5 Current peak on changeover from star to delta
6 Mechanical load on changeover from star to delta
Application of Star-Delta Starter
The star-delta method is usually only applied to low to medium voltage and light starting
Torque motors
The received starting current is about 30 of the starting current during direct on line start and the
starting torque is reduced to about 25 of the torque available at a DOL start This starting
method only works when the application is light loaded during the start If the motor is too heavily
27 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
loaded there will not be enough torque to accelerate the motor up to speed before switching over
to the delta position
LESSON 1 WIRING SYSTEM OF SINGLE PHASE DISTRIBUTION BOARD
Introduction
28 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
29 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
30 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
31 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 2 WIRING SYSTEM OF SINGLE PHASE LIGHTING CIRCUIT Introduction
Objectives
1 Identify component and the specification
2 Wire component according to the schematic diagram
3 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Wiring bay Perforated metal 180 cm x 180 cm 1
2 Cut out fuse 63 A 240 V 1
3 Neutral link 1
4 Single pole one way switch cw
switch box
5A 240Vac 4
5 single pole two way switch cw
switch box
5A 240Vac 2
6 RCCB In = 40 A Tripping current
100mA240 Vac 50 Hz
1
7 Main switch 32 A 240V 1
8 kWatthour meter 40 A 240 Vac 1
9 Single pole MCB 6A 240 Vac 1
10 Self tapping Wood screw As required
11 DIN rail 35 mm width As required
32 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
12 PVC trunking 50 mm x 50 mm As required
13 Terminal blocks 5 A As required
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
1 One way switch to control one lamp
2 One way switch to control two lamps
3 Two of two way switch to control one lamp
4 Two of single pole two way switch and one of an intermediate switch to control one
lamp
5 One unit of ceiling fan and fan regulator to be controlled by one way switch
4 Test the functionality of completed project
LESSON 3ndash WIRING SYSTEM OF SINGLE PHASE POWER CIRCUIT Introduction
33 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
34 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify types of component and its specification
2 Wire component according to the schematic diagram given
3 Test the functionality of the circuit dead circuit test life circuit test
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board Perforated Metal 1
2 kWh meter 240 V 40 A 1
3 Socket outlet 13A 240Vac 4
4 RCCB 40A Trip Amps
30mA240 Vac
1
5 3 pin socket 240Vac 13A 4
6 Single pole MCB 20A 240 V 2
7 DOL starter 1 kW 240Vac 2
8 1 phase induction motor 2Hp 240 Vac 1
9 Cooker control unit 4kW 240Vac 1
10 Water heater point 4kW 240 Vac 1
11 DIN rail 35 mm As required
12 PVC casing 20mm As required
13 Flexible wires 05 mm As required
14 Terminal block 10 A As required
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Wire two unit of 13 A socket outlet in radial circuit
3 Wire four units of 13 A socket outlet in ring circuit
4 Wire one unit DOL starter for air-conditioner point
5 Wire one unit of cooker control unit point
6 Wire one unit of water heater point
7 Test the functionality of each component by using mmeter or power supply whichever
applicable
8 Wire component according to circuit diagram
9 Test the functionality of completed project dead circuit test life circuit test
Note
35 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Ensure that the correct rating of protection device and size of wire used
LESSON 4ndash CONDUIT BENDING AND TRUNKING FABRICATION TECHNIQUE
Common fitting used in an industrial wiring
Cutting and threading the condute
36 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
37 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
38 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify conduit fitting and the specification
2 Measure and Cut steel conduit according to specified dimension
3 Bend and fabricate conduit at 45 90 according to layout diagram
4 Wire component according to the schematic diagram
5 Test the functionality of the circuit
39 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Conduit Bender Oslash 19 mm ( frac34 ldquo) 1
2 Measuring Tape 3 metre 1
3 Hacksaw frame and blade 30cm 1
4 Conduit cutter 1
5 Pipe Vise 1
6 Pipe Wrench 1
7 Ratchet Dies 20 mm 1
8 Metal trunking 50 mm x 50 mm 1
9 GI conduit 20mm 1
10 End box 20 mm 1
11 Flexible wires 05 mm As required
12 Connectors 5 A As required
13 Single core PVC ins Cable 25 mm 2 As required
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Wire two unit of 13 A socket outlet in radial circuit
3 Wire four unit of 13 A socket outlet in ring circuit
4 Wire one unit DOL starter for air-conditioner point
5 Wire one unit of cooker control unit point
6 Wire one unit of water heater point
7 Test the functionality of each component by using multimeter or power supply whichever
applicable
8 Wire component according to circuit diagram
9 Test the functionality of completed project
Note
Ensure that the rating of protection device and size of wire
K prior to 31 March
2004 (BS 7671)
(formerly)
bare conductor
sleeved at terminations (formerly)
40 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 5 ndashWIRING SYSTEM OF 1 Oslash LIGHTING AND POWER CIRCUIT
POWER CIRCUITSa Radial circuits
Radial circuits are arranged in the same way as item 1 above in lighting layouts in that each socket
outlet is supplied via the previous one
Points to note
1 The number of socket outlets complying with BS 1363 is unlimited for a floor area of up to 50m 2 if
the circuit protection is a 30 A or 32 A cartridge fuse or circuit breaker the cable being 4 mm PVC
copper or 25 mm2 mineral insulated (mi)
2 The number of socket outlets is unlimited for a floor area up to 20 m 2 with any type of circuit
protection of 20 A using 25 mm2 PVC copper cable or 15 mm2 mi
3 The total number of fused spurs is unlimited
b ring final circuits
These circuits are the same as radial circuits except that the final socket outlet is wired back to the
supply position In effect any outlet is supplied from two directions (Fig 152)
Points to note
1 Every twin-socket outlet counts as two single-socket outlets
2 The number of non-fused spurs must not exceed the total number of points on the ring Fig 158
shows seven points on the ring and five spurs
3 The fuse rating of a fused spur box must not exceed 13 A and the current rating of all points supplied
by the fused spur must not exceed 13 A
4 Non-fused spurs must supply no more than one single or one double socket on the ring Fig 158
shows seven points on the ring and five spurs rating of all points supplied by the fused spur must not
exceed 13 A or one stationary appliance
CapacityMain conductor size
copper (mm2)
Earth conductor
size (mm2)
Circuit breaker
capacity (A)
Up to 600 W 15 15 6
600ndash1200 W 1525 15 10
1200ndash1800 W 254 25 16
41 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Ring circuit
(floor area 100 m2)25 15 3032
A2 radial circuit
(floor area 75 m2)40 25 3032
A3 radial circuit
(floor area 50 m2)25 15 20
Air conditioner (15 tonne) 60 60 3032
Cooker 60 60 3032
Water heater 40 40 20
Objectives
1 Identify component and the specification
2 Wire component according to the schematic diagram
3 Test the functionality of the circuit
42 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board Perforated 1
2 Cut out fuse and neutral link 60A 240V 1each
3 kWh meter 240V 40A 1
4 Switched Socket outlet 13A 240Vac 4
5 Single pole two way switch cw switch
box
5A 240Vac 2
6 RCCB ELCB 63 A Tripping current 100mA
415 Vac
1
7 3 pin plug 240Vac 13A 4
8 Single pole MCB 20 A 2
9 Single pole MCB 6A 1
10 Single pole MCB 20A 2
11 DOL starter 240Vac 2
12 1 phase induction motor 2hp 240 Vac 1
13 Self tapping Wood screw As required
14 DIN rail Stainless steel allum35 mm As required
15 PVC pipe 20mm dia As required
16 End box 20 mm dia 4
17 Flexible wires 05 mm 2 As required
18 Connectors 5 A As required
Procedures
43 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
4 Test the functionality of completed project
LESSON 6 ndash WIRING SYSTEM OF 3 Oslash DISTRIBUTION BOARD
Introduction
44 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
45 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
46 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
47 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
48 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify each component and the specification
2 Wire component according to the schematic diagram given
3 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting Board 450 x 600 mm Perforated metal 1
2 5 pin round socket and plug 415V ac 32A 1
3 Cut out fuse 60 A 3
4 Neutral link 1
5 kWatt hour meter 415V 60A 1
6 ELCB RCCB 3P+N In=63A415 Vac I trip= 300mA 1
7 ELCB RCCB 3P+N In=63A415 Vac I trip= 30mA 1
8 Single pole MCB 6A 240 V 3
9 Single pole MCB 20A 240 V 3
10 DOL starter 20 A 240Vac 2
11 Socket outlet 15 A 240 Vac 1
12 Switched Socket outlet 13 A 240 Vac 3
13 Led indicating light 5A 240 Vac 3
14 Single pole 4 gang 1 way switch 5A 240 Vac 2
15 Single pole 2 way switch 5A 240 Vac 2
16 1 phase induction motor 1 kW 240Vac 1
17 Metal trunking 30 mm x30 mm As required
18 Self tapping Wood screw 4 mm x 20 mm As required
19 DIN rail 25 mm x 1mm
20 GI steel rigid conduit 20mm As required
21 Flexible conduit 20mm As required
22 End box 20 mm 4
23 Flexible wires 05 mm 2 As required
24 Single core PVC insulated wire 15 mm 2 As required
25 Single core PVC insulated wires 25 mm 2 As required
26 Terminal block 10 A As required
Procedures
49 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify each components and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
4 Test the functionality of completed project
1 dead circuit test
2 life circuit
Note Proper earthing should be made
50 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 7 ndash WIRING SYSTEM OF THREE PHASE LIGHTING AND POWER CIRCUIT
51 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
52 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify component and the specification
2 Wire component according to the schematic diagram
3 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting bay Board Perforated metal 180 cm x 180 cm 1
2 k Watt hour meter 415V 60A 1
3 MCCB 415V 60A
4 ELCB RCCB In=60A415 Vac I trip=30mA 1
5 5 pin round Socket and
plug
415Vac 32A 4
6 Single pole MCB 6A 1
7 Triple pole MCB 20A 2
8 Triple pole Main switch 60A 1
9 DOL starter 240Vac 2
10 3 phase induction motor 2hp 415 Vac 1
11 1 phase induction motor 1
12 Metal trunking 30 mm x30 mm As required
13 Self tapping Wood screw 4 mm x 20 mm As required
14 DIN rail 25 mm x 1mm
15 GI steel rigid conduit 20mm As required
16 Flexible conduit 20mm As required
17 End box 20 mm 4
18 Flexible wires 05 mm As required
19 Connectors 10 A As required
Procedures
1 Identify each components and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
4 Test the functionality of completed project
1 dead circuit 2 life circuit test
5 Record the current drawn by the load as connected in star and delta
Note Proper earthing should be made
53 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 8 INSPECTION AND TESTING OF ELECTRICAL INSTALLATION
On completion of a wiring installation a number of tests on the installation have to be conducted to
ascertain that the wiring circuits and connected appliances are safe for use Prior to carrying out the
tests an inspection has to be done The results of the inspectionsupervision and test have to be
presented in Form G (as in Appendix IV) and Form H (as in Appendix V)
To have the test certification as in Form H the following tests shall be conducted
i Continuity Test
ii Insulation Resistance Test
iii Polarity Test
iv Earth Electrode Resistance test and
v Residual Current Device Test
1 Continuity Test
There are 3 main types of continuity tests for the final circuits-
i Protection Conductor Continuity Test
ii Final Ring Circuit Conductor Continuity Test
iii Live and Neutral Conductor Continuity Test
a) Protection Conductor Continuity Test
bull To ascertain that all protection conductors are connected in the correct and effective manner
bull Test equipment ndash Multimeter (Ohm range) or Ohm meter
54 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
bull Test Method
1 1048766 Ensure that the main switch RCD and MCB are open circuited (switched off) and all loads
are disconnected
2 1048766 Connected the test leads as in the Figure 81 The meter reading shall be less than 1 Ω
55 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Final Ring Circuit Conductor Continuity Test
bull To ensure that all conductors around the ring circuit have continuity
bull Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
bull Test Method
1 1048766 Disconnect both the supply source live conductors from the MCB the neutral conductor
from the neutral terminals and the earth conductor from the earth terminal in the distribution
fuse box
2 1048766 Connect the test leads as in the Figure 82 (EE)
3 1048766 Repeat the procedure for (L-L) and (N-N)
4 1048766 The meter reading value shall be less than 1 ohm
56 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Live and Neutral Conductor Continuity Test
a To ensure that each conductor in the circuit has continuity
b Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
2 Test Method
1 1048766 Switch off the Main switch RCD and MCB
2 1048766 Disconnect all loads
3 1048766 Switch on all switches in the circuit
4 1048766 Disconnect the fusesfinal circuit breakers and close the circuit
5 1048766 Carry out the test as shown in Figure 83
6 1048766 The meter reading value shall be less than 1Ω
57 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
58 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
CONTINUITY TEST
Insulation Resistance Test
i Ensure that there is no leakage current between phase conductors phase and neutral conductors and
phase conductor and earth
ii Test the strength of the cable insulation
iii Test Equipment ndash Insulation Resistance Tester operating voltage is 250VDC or 500VDC
iv Test Method
1 1048766 Switch off main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
59 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
4 1048766 Carry out test as in the Table below
5 1048766 Meter reading value shall be less than 1 Megaohm
60 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
61 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Insulation resitance test
62 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
INSULATION RESISTANCE TEST BETWEEN CONDUCTORS AND OPPOSITE POLARITY
Polarity Testi Ensure that each fuse or single pole control and protection device is connected only in the phase
conductor
ii Intermediate contact of Edison screw lamp holder is connected to the phase conductor
iii Ensure that phase neutral and earth conductors at socket outlets are connected at the correct
terminals
iv Test Equipment ndash Multimeter (Ohm range) or Ohm meter
v Test Method
1 1048766 Switch off Main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in Figure 85
63 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
5 1048766 Test switches and single phase control devices at the phase conductors
6 1048766 Test socket outlet connection sources
7 1048766 Test Edison screw lamp holder connections
8 1048766 Meter reading value shall be less than 1 Ω
64 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Polarity test
65 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Earth Electrode Resistance Testi To test the earth electrode resistance
ii To ascertain the suitability of the location of the electrode
iii To ensure that the electrode is not buried within the resistance area of another electrode
iv Test equipment ndash Earth Resistance Tester
v Test method -
1 1048766 Terminal rsquoErsquo is connected to the electrode to be tested (green conductor)
2 1048766 Terminal lsquoPrsquo is connected to the potential spike (yellow conductor) at a distance of 10
meters from the earth electrode
3 1048766 Terminal lsquoCrsquo is connected to the current spike (red conductor) at a distance of 20 meters
from the earth electrode
Earth Electrode Resistance Measurement Method (Figure 86)
This test must be repeated at least three times to ensure that the reading is not affected by interacting
earthing regions
i Record the first reading (Z1) Example Z1 = 10 Ω
ii Move the voltage spike to a distance of 6 meters from the original position Record the second
reading (Z2 ) Example Z2 = 10 Ω
iii Move the voltage spike to a distance of 6 meters from the original position Record the third
reading (Z3) Example Z3 = 10 Ω
66 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Residual Current Device Testi Ensure that the residual current device (RCD) trips within the set time on the occurrence of current
leakage to earth
ii Test Equipment ndash RCD Tester RCCB Tester
iii Test Method 1
1 1048766 Use the Trip Test Button
2 1048766 Press the trip button found on the RCD to determine if it trips or otherwise This test would
not be able to determine the sensitivity of the RCD nor the time taken for it to trip
iv Test Method 2
i 1048766 Use a RCD Tester
ii This equipment is equipped with a 13A plug which can be connected to a 13A socket outlet
Select the RCD sensitivity to be the same as the sensitivity of the RCD to be tested to
determine if the RCD can trip The time to trip shall not exceed 40 mS
iii 1048766 Test method ndash
a) Position the selection switch in accordance with the sensitivity of the RCD used
Example 100 mA 01 A
b) Position the operations switch to lsquoNo Triprsquo (frac12 Rated mA = 50) connect the 3 pin plug to
the 13A socket outlet
67 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
c) Switch on the 13A socket outlet ndash ensure that the P-N and P-E lights light up
This shows that the polarity is correct (Note if both the lights as above do not light up the test cannot
be continued)
d) Press the test button ndash the reading shows less than 200 mS and simultaneously the lsquotestrsquo light lights
up and the P-N and P-E lights do not light up At that instant the RCD will not trip
e) Move the selection switch to 180o (+ve wave) ndash repeat steps (d) and (e) Move the operations
switch to lsquoTriprsquo (Rated mA = 100)
g) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200mS
h) Move the selection switch to 0o (-ve wave)
i) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
j) The above test is repeated until a near correct reading is obtained
k) Record the test results
l) Change the operations switch to lsquoFast Triprsquo and press the test button ndash RCD will trip within a
time not exceeding 40 millisecond
m) Repeat a number of times at 0o or 180o
On completion of a wiring installation a number of tests on the installation have to be conducted to
ascertain that the wiring circuits and connected appliances are safe for use Prior to carrying out the
tests an inspection has to be done the following tests shall be conducted
i Continuity Test
ii Insulation Resistance Test
iii Polarity Test
iv Earth Electrode Resistance test and
v Residual Current Device Test
821 Continuity Test
There are 3 main types of continuity tests for the final circuits-
i Protection Conductor Continuity Test
ii Final Ring Circuit Conductor Continuity Test
68 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
iii Live and Neutral Conductor Continuity Test
a) Protection Conductor Continuity Test
bull To ascertain that all protection conductors are connected in the correct and effective manner
bull Test equipment ndash Multimeter (Ohm range) or Ohm meter
bull Test Method
1 1048766 Ensure that the main switch RCD and MCB are open circuited (switched off) and all loads are
disconnected
2 1048766 Connected the test leads as in the Figure 81
3 1048766 The meter reading shall be less than 1 Ω
Final Ring Circuit Conductor Continuity Test
bull To ensure that all conductors around the ring circuit have continuity
bull Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
bull Test Method
1 1048766 Disconnect both the supply source live conductors from the MCB the neutral conductor
from the neutral terminals and the earth conductor from the earth terminal in the distribution
fuse box
2 1048766 Connect the test leads as in the Figure 82 (EE)
3 1048766 Repeat the procedure for (L-L) and (N-N)
4 1048766 The meter reading value shall be less than 1 ohm Figure 82 - Final Ring Circuit Conductor
Continuity Test Ohm Meter
Disconnect both the supply source cables from mcbfuse
Take readings at earth conductors of both sources and note resistance readings
Live and Neutral Conductor Continuity Test
1 To ensure that each conductor in the circuit has continuity
2 Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
3 Test Method
1 1048766 Switch off the Main switch RCD and MCB
2 1048766 Disconnect all loads
3 1048766 Switch on all switches in the circuit
4 1048766 Disconnect the fusesfinal circuit breakers and close the circuit
5 1048766 Carry out the test as shown in Figure 83
6 1048766 The meter reading value shall be less than 1 ohm Figure 83 - Live and Neutral
Conductor Continuity Test Ohm Meter
Insulation Resistance Test
69 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
i Ensure that there is no leakage current between phase conductors phase and neutral conductors and
phase conductor and earth
ii Test the strength of the cable insulation
iii Test Equipment ndash Insulation Resistance Tester Operating voltage is 250VDC or 500VDC
iv Test Method
1 1048766 Switch off main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in the Table below
5 1048766 Meter reading value shall be less than 1 Megaohm
Polarity Test
i Ensure that each fuse or single pole control and protection device is connected only in the phase
conductor
ii Intermediate contact of Edison screw lamp holder is connected to the phase conductor
iii Ensure that phase neutral and earth conductors at socket outlets are connected at the correct
terminals
iv Test Equipment ndash Multimeter (Ohm range) or Ohm meter
v Test Method
1 1048766 Switch off Main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in Figure 85
5 1048766 Test switches and single phase control devices at the phase conductors
6 1048766 Test socket outlet connection sources
7 1048766 Test Edison screw lamp holder connections
8 1048766 Meter reading value shall be less than 1 Ω
Earth Electrode Resistance Test
i To test the earth electrode resistance
70 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
ii To ascertain the suitability of the location of the electrode
iii To ensure that the electrode is not buried within the resistance area of another electrode
iv Test equipment ndash Earth Resistance Tester
v Test method -
1 1048766 Terminal rsquoErsquo is connected to the electrode to be tested (green conductor)
2 1048766 Terminal lsquoPrsquo is connected to the potential spike (yellow conductor) at a distance of 10
meters from the earth electrode
3 1048766 Terminal lsquoCrsquo is connected to the current spike (red conductor) at a distance of 20 meters
from the earth electrode E P C Electrode 10 meter 10 meter
Figure 86 ndash Earth Electrode Resistance Measurement Test Equipment
Earth Electrode Resistance Measurement Method (Figure 86)
This test must be repeated at least three times to ensure that the reading is not affected by interacting
earthing regions
i Record the first reading (Z1) Example Z1 = 10 Ω
ii Move the voltage spike to a distance of 6 meters from the original position Record the second
reading (Z2) Example Z2 = 10 Ω
iii Move the voltage spike to a distance of 6 meters from the original position Record the third
reading (Z3)
Example Z3 = 10 Ω
Residual Current Device Test
71 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
i Ensure that the residual current device (RCD) trips within the set time on the occurrence of current
leakage to earth
ii Test Equipment ndash RCD Tester RCCB Tester
iii Test Method 1
1 1048766 Use the Trip Test Button
2 1048766 Press the trip button found on the RCD to determine if it trips or otherwise This test would
not be able to determine the sensitivity of the RCD nor the time taken for it to trip
iv Test Method 2
1048766 Use a RCD Tester
This equipment is equipped with a 13A plug which can be connected to a 13A socket outlet Select the
RCD sensitivity to be the same as the sensitivity of the RCD to be tested to determine if the RCD can
trip The time to trip shall not exceed 40 mS
1048766 Test method ndash
a) Position the selection switch in accordance with the sensitivity of the RCD used
Example 100 mA 01 A
b) Position the operations switch to lsquoNo Triprsquo (frac12 Rated mA = 50) connect the 3 pin plug to
the 13A socket outlet
c) Switch on the 13A socket outlet ndash ensure that the P-N and P-E lights light up This shows that
the polarity is correct (Note if both the lights as above do not light up the test cannot be
continued)
d) Press the test button ndash the reading shows less than 200 millisecond and simultaneously the
lsquotestrsquo light lights up and the P-N and P-E lights do not light up At that instant the RCD will
not trip
e) Move the selection switch to 180o (+ve wave) ndash repeat steps (d) and (e) = 100)
f) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
g) Move the selection switch to 0o (-ve wave)
h) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
i) The above test is repeated until a near correct reading is obtained
j) Record the test results
k) Change the operations switch to lsquoFast Triprsquo and press the test button ndash RCD will trip within a
time not exceeding 40 mS
l) Repeat a number of times at 0o or 180o
72 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 9 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (DC)
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
73 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Start stop button 240Vac 5A 2
9 Filament lamp (Bulb ) 240Vac 40W 3
10 Overload Relay 415V 20A 3
11 Three phase induction motor 5 hp 3
12 Single phase step down transformer 2500VA 1
13 Single core PVC insulated Cable 1mm 2 As required
14 Single core PVC insulated Cable 25mm 2 As required
15 DIN rail 35 mm As required
16 PVC type Cable tray 50 mm x 50 mm As required
17 Cable ties 4 ldquo As required
18 Flexible wires 05 mm As required
19 PVC Connectors 5 A amp 20 A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the schematic
diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a optional exercise
i Simple DOL starter
ii Forward reverse DOL starter
iii Forward Reverse Dahlander motor
iv Three motors operated in sequence by DOL starter operated by manual push
button or time delay relay
74 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
a One loop per-cycle
b Continuous operation in a loop
c optional circuit design to represent the same task
v Only one out of three motors to be operated at a time (quiz)
4 Test the functionality of completed project
LESSON 10 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (AC)
75 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 1
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Lamp point 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
76 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
11 Overload Relay 415V 20A 3
12 Three phase induction
motor
5 hp 3
13 Single core PVC insulated
Cable
1mm 2 As required
14 Single core PVC insulated
Cable
25mm 2 As required
15 DIN rail 35 mm As required
16 PVC type Cable tray 50 mm x 50 mm As required
17 Cable ties 4 ldquo As required
18 Flexible wires 05 mm As required
19 PVC Connectors 5 A amp 20 A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the
schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram optional exercise
4 Simple DOL starter
5 Forward reverse DOL starter
6 Test the functionality of completed project
77 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 1
78 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
cm
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Indicating light 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
11 Overload Relay 415V 20A 3
12 Three phase induction motor 5 hp 3
13 Single phase step down
transformer
2500VA 1
14 Single core PVC insulated
Cable
1mm 2 As required
15 Single core PVC insulated
Cable
25mm 2 As required
16 DIN rail 35 mm As required
17 PVC type Cable tray 50 mm x 50 mm As required
18 Cable ties 4 ldquo As required
19 Flexible wires 05 mm As required
20 PVC Connectors 5 A amp 20 A 240 V As required
21 Single pole MCB 6A 240 V 1
22 Single pole MCB 2A 240 V 1
23 Triple pole MCB 20A 415 V 1
24 Mounting board 30 cm x 40 cm x 3
cm
1
25 Relay cw 11 pin socket 10 A 240 Vac 2
26 Time delay relay 10 A 240 Vac 3
27 Triple pole Contactor 20A 240Vac 3
28 Batten type Lamp holder 240Vac 10 A 3
29 Start stop button 240Vac 10A 2
30 Indicating light (Bulb ) 240Vac 25W 3
31 Overload Relay 415V 20A 1
32 Three phase dahlander type
induction motor
5 hp 1
33 Single phase step down
transformer
24024Vac
2500VA
1
79 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
34 Single core PVC insulated
Cable
1mm 2 As required
35 Single core PVC insulated
Cable
25mm 2 As required
36 DIN rail 35 mm As required
37 PVC type Cable tray 50 mm x 50 mm As required
38 Cable ties 4 ldquo As required
39 Flexible wires 075 mm As required
40 PVC Connectors 5 A amp 20 A 240 V As required
41 Terminal block 20A 240Vac As required
Procedures
5 Identify each component according to specification and quantity required from the schematic
diagram attached
6 Test the functionality of each component by using multi-meter or power supply whichever
applicable
7 Wire component according to circuit diagram
8 Three motors operated in sequence by DOL starter operated by manual push button or time
delay relay
a One loop per-cycle
b Continuous operation in a loop
c optional circuit design to represent the same task
d Only one out of three motors to be operated at a time (quiz)
9 Test the functionality of completed project
80 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
BASIC DESIGN INDUSTRIAL MOTOR CONTROL (SEQUENCE CONTROL)
THREE PHASE INDUCTION MOTOR OPERATED IN SEQUENCE BY DIRECT ON LINE
STARTER
LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
81 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
82 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Lcd lamp indicator 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
11 Overload Relay 415V 20A 3
12 Three phase induction motor 5 hp 3
13 Single phase step down transformer 2500VA 1
14 Single core PVC insulated Cable 1mm 2 As required
15 Single core PVC insulated Cable 25mm 2 As required
16 DIN rail 35 mm As required
17 PVC type Cable tray 50 mm x 50 mm As required
18 Cable ties 4 ldquo As required
19 Flexible wires 1 mm Oslash As required
20 PVC Terminal block 10A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the schematic
diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a optional exercise
i Forward Reverse dahlander motor
4 Test the functionality of completed project
83 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
THREE PHASE DAHLANDER TYPE INDUCTION MOTOR OPERATED FORWARD AND
REVERSE OPERATION BY DIRECT ON LINE STARTER
84 ndash 99EASYTECH ENTERPRISE
LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
Introduction
If a motors windings are connected in the star configuration any two phases will be in series across
the supply and hence the line current will be smaller(by 577) than if the windings were connected in
the delta arrangement
Hence larger-type motors with heavy starting currents are first connected in star and then when the
starting currents fall in delta This of course means that all six of the ends of the windings must be
brought to terminations outside the casing (Fig 833)
EZTECH
EZTECH ELECTRICAL INSTALLATION GUIDE
The automatic version of this starter incorporates a timing relay which automatically changes the
connections from star to delta Figs 834 and 835 show the wiring and schematic diagrams for a star
delta starter
Objectives
1 Identify component and the specification
2 Design forward reverse star delta starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
2 ndash 99EASYTECH ENTERPRISE
REV -C
LEGENDMCCB Moulded Case Circuit BreakerTOR Thermal Over Load RelayFOW-C Mains Forward ContactorREV-C Mains Reverse ContactorDC Delta ContactorSC Star ContactorS-SW Mains Selector Switch
SC
V2
W2
U2
DC
V1
W1
U1
TOR
TOR
FOW-C
30A MCCB
TOR
MAIN CIRCUIT FORWARD REVERSE STAR DELTA
RYBN S
-SW
3 PHASEINDUCTION MOTOR
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Relay 10 A 240V 3
5 Triple pole Contactor
6 cw NO NC auxiliary contact
240Vac 20 A 4
7 Overload Relay 415 V 1
8 LED indicator 240vac 5 A 4
9 Start stop button 240Vac 5A 2
10 DIN rail 35 mm As required
11 Flexible wires 1 mm As required
12 Single core PVC insulated
wire
25 mm As required
13 Terminal block 20 A As required
14 Squirrel cage motor 5kW 1
15 5 pin plug and socket 415V 20A 1
16 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
3 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
a Manual star delta
b Manual Forward reverse star delta starter
c Automatic star delta starter
d Automatic Forward reverse star delta starter
4 Test the functionality of completed project
4 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
Objectives
1 Identify component and the specification
2 Design auto transformer starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
5 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Autotransformer starter is used to start a 3 phase induction motor that has a rating between 10 to 15 hp
6 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Autotransformer set 10Kw 415 V 50 Hz 1
5 Triple pole Contactor 240Vac 4
6 Batten type Lamp holder 240 Vac 105 A 4
7 Start stop button 240Vac 10A 4
8 Filament lamp (Bulb ) 240Vac 40W 4
9 DIN rail 35 mm As required
10 Flexible wires 1 mm As required
7 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
11 Single core PVC insulated
wire
25 mm As required
12 Terminal block 20 A As required
13 Squirrel cage motor 10kW 1
14 5 pin plug and socket 415V 20A 1
15 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a open transient autotransformer starter
b close transient autotransformer starter
c Forward reverse autotransformer starter
4 Test the functionality of completed project
8 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
Objectives
1 Identify component and the specification
2 Design rotor resistance starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
9 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Rotor Resistor set 10kW 1
5 Triple pole Contactor 240Vac 20A 4
6 Indicating light 240vac 5 A 4
7 Start stop push button 240Vac 5A 4
8 DIN rail 35 mm As required
9 Flexible wires 1 mm 2 As required
10 Single core PVC insulated wire 25 mm 2 As required
11 Terminal block 20 A As required
12 Slip Ring motor 10kW 1
13 5 pin round 3 phase socket 415V 20A 1
14 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
10 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
4 Test the functionality of completed project
a Dead circuit test b Life circuit test
5 Measure starting and running Amps
LESSON 16
TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
An installation in general will suffer damage
Damage usually occurs on the electric motor control as follows
1 Damage to the main circuit
2 Damage to the control circuit
The cause of the damage
i Overcurrent overload short circuit
ii Leakage current to ground
iii Equipment malfunction
iv The main control circuit
a Trip of main circuit protection devices fire
b Defect of motor terminal such as short circuit fire loose
v The control circuit is not functioning -
a contactor relay relay time overload relay does not work damaged burned
b Loose cable connection disconnected
Detecting and Repairing Damage
Examples of damage are as follows
i Motor does not work
ii Motor function and overload relay trips
iii Motor function but only partially functional control circuit
Methods of detecting damage
Among the known methods necessary to detect damage are as follows
1 Turn off the electricity at the main switch (main switch) in order to avoid any danger during the
work carried out to detect damage
2 Check all the protective gear that controls the motor control main circuit
11 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
3 Make sure the damage function control circuit
4 Check the control circuit according to the schematic circuit diagram of the motor control
5 Check the operation of the control circuit
Note
Use wiring that has been installed on the SYSTEM OF MOTOR CONTROL BOARD by Forward
Reverse control circuit for Star Delta to test and look for damage
SELF-ASSESSMENT QUESTIONS
1 (a) Explain what is meant by the term lsquoback emfrsquo in a motor
(b) Outline the basic differences between series shunt and compound wound dc motors
2 (a) With the aid of diagrams explain how the speed of series shunt and compound-wound motors
may be controlled
(b) A 440V dc shunt-wound motor has a field resistance of 200R and an armature resistance of 06 R
When its speed is 20 rev d second the current drawn from the supply is 122A Calculate its back
emf at this speed If the speed were decreased to 19 revssecond the field flux remaining unchanged
calculate the new back emf and the new armature current
3 A load of 64 kW at 240 V is supplied from the terminals of a shunt-wound dc generator The field
resistance is 180 A Calculate the armature current
4 (a) Explain with the aid of a diagram how a rotating magnetic field may be
(b) What is meant by lsquosynchronous speedrsquo
Calculate the synchronous obtained speed of a 12 pole motor if the supply frequency is 50Hz
5 (a) Explain the action of a synchronous motor
(b) What methods are available to start a synchronous motor Explain with diagrams
6 (a) Explain the action of a cage induction motor
(b) What is meant by the term lsquosliprsquo
Calculate the percentage slip of a six pole induction motor running at 162 revssecond from a 50 Hz
supply
7 Describe with sketches three different ways of starting a single-phase induction motor
12 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
8 Explain with the aid of a sketch the action of a three-phase DOL starter
What are dashpots used for How are remote start and stop buttons connected
9 A I0 kW 240V 50Hz single-phase cage rotor induction motor is 85efficient and has a PF of 068
lagging Calculate the motor current and the value of capacitor required to raise the PF to 093
lagging
10 Calculate the torque developed by an 18 kW four-pole induction motor run at 35 slip from a
50Hz supply
APPENDIX 1
13 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 11
14 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 111
Attachment Reference
httpswwwtlc-directcoukBook621htm
httpwwwstgovmyindexphpms
15 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
This is the conductor which is connected between the consumer earthing point and the exposed
metallic part The minimum cable size for this purpose is 10 mm2
iii Protection Conductor
This is the conductor which connects the consumer earthing point with other parts of the installation
which needs earthing Its size is as follows-
a) Same size as the phase cable up to a size of 16mm2
b) 16 mm2 if the phase cable size is between 16 mm2 and 35 mm2
c) Half the size of the phase cable if the size of the phase cable exceeds 35 mm2
54 Earthing Arrangements Using a TT System
i The first alphabet indicates the earthing arrangements from the supply side
ii The second alphabet indicates the earthing arrangement in the consumerrsquos installation
T ndash first Indicates that the supply system has its own earthing arrangements
T ndash second Indicates that all metallic frames of the electrical appliances etc are connected directly to
earth
Parts that are Required to be Earthed
i All metallic structures in the wiring system (non current carrying) such as metallic covers conduits
ducts the armour of catenary wires etc
ii A secondary winding point in a transformer and
iii Frame of metal roof truss
56 Parts that are not Required to be Earthed
i Short isolated metallic parts for mechanical protection of cables which have non metallic sheaths
other than conduits which are connected at entry points between the building and conduits which
protect discharge lamp cables
ii Cable clips for installing cables
iii Metallic covers for lamps
16 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
iv Small metallic parts such as screws and name plates which are isolated by means of insulation
v Metallic lamp parts for filament lamps in water proof floors
57 Termination to Earth
The termination to earth is done as shown in Figure 72
Earth Electrode Resistance
The maximum permitted earth electrode resistance for different types of installations is as shown in
the Table below
Earth electrode for installations protected by RCDs of sensitivity 100mA 10 Ω
Lightning arrestor earth electrode 10 Ω
Legal Requirements
i Sub regulation 12(1) and 12(2) of the Electricity Regulations 1994 state that any electrical wiring in
an installation shall be under the immediate supervision of a Wireman with Single Phase Restriction or
Three Phase Restriction Upon completion the Wireman shall certify a Supervision and Completion
Certificate
ii Sub regulation 13(1) and 13 (2) of the Electricity Regulations 1994 state that the installation shall
be tested by a Wireman with Single Phase Restriction or a Wireman with Three Phase Restriction
authorized to test any installation and who shall certify a Test Certificate for the installation
iii Sub regulation 14(1) of the Electricity Regulations 1994 states that the Supervision and
Completion Certificate and the Test Certificate as in regulations 12 and 13 shall be in Forms G and H
respectively as prescribed in the First Schedule
17 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
4 SAFETY REQUIREMENTS FOR ELECTRICAL WIRING WORKS IN RESIDENTIAL BUILDINGS
61 Safety Requirements
Safety requirements for electrical wiring works have to be followed to eliminate any accidents which
can result in physical damage or loss of life or property Failure to meet the safety regulations may
result in workers consumers or the public being inflicted with electrical shocks
In addition to this safety steps will also encourage workers or electricity consumers who are
disciplined and who always give importance to safety
62 Safety Steps
Safety requirements have to be followed whenever electrical works are undertaken in a residential
building
i Personal Safety
a Use suitable personal protection equipment as needed such as safety shoes gloves safety helmet
etc when at the work place
b Use safety clothing suitable for the work to be undertaken
c Do not wear jewellery or decorative items such as rings watches chains etc while carrying out
electrical works
ii Safety at the Work Place
a Acquire knowledge about the dangers of electrical works that is to be undertaken and how to deal
with those dangers
b Always adhere to the safety regulations which have been set for the work place
c Ensure that the electricity supply is switched off before carrying out the works
d Acquire the needed knowledge and practice a cautious and calm attitude while working ensure
cleanliness in and around fellow workers
e While working at elevated places the worker should always use suitable equipment such as wooden
or aluminium ladders iron scaffoldings or platforms safety belts or other equipment needed to ensure
that the work can be undertaken safely
f Use electrical equipment which is operational and safe to be used and ensure that the supply for it is
being supplied through a residual current device (RCD) with a sensitivity of 30 mA
g Ensure that exposed temporary supply electrical cables have mechanical protection
h If inflammable or corrosive material is present necessary safety steps have to be undertaken as
required by the relevant safety regulations
63 Dangers of Electrical Shocks
i Electrical Shock
Electrical shocks can occur due to direct or indirect contact
a Direct Contact
18 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Direct contact occurs when the worker or consumer receives an electrical shock on touching directly a
live conductor or cable
b Indirect Contact
Here the electric shock occurs due to contact with a part which is connected to the electrical
installation and not to a direct contact with a live cable or conductor possibly due to damages in the
appliance or insulation resulting in leakages of current
Why Electric Shocks Occura Unsafe Work Method or Action Undertaking Electrical Work Without Disconnecting the
Supply
Maintenance or circuit testing work done without disconnecting the supply will have a high possibility
of electrical shocks occurring
bull Not Following Safe Work Procedures
To eliminate the occurrence of electrical shocks each worker has to always follow safe work
procedures which are set by regulations and standards
b Defects in the Electrical System
i Leakage Current
Leakage currents or earth leakage currents can result in the metallic frames becoming live and
energised This can give rise to the danger of electrical shock to the worker consumer or the public if
they hold or come into contact with the metallic frame
ii Exposed Conductor or Disconnected Cable
Exposed conductors or cables which are broken and are alive (energised) can result in electrical shock
when touched The supply source must be immediately isolated or switched off and a report must be
made to the responsible entity
64 First Aid and Basic Pulmonary Resuscitation
i First Aid
First aid is the initial assistance given to a person who has met with an accident is sick or is injured to
prevent the condition of the victim from becoming more serious while awaiting the arrival of the
paramedics (ambulance) or before being brought to the hospital
i Pulmonary Resuscitation
Pulmonary resuscitation has to be undertaken to assist the victim who has breathing difficulties as a
result of being drowned receiving an electrical shock etc Pulmonary resuscitation has to be carried
out in accordance to the correct method as stated in the first aid manuals issued by accredited first aid
bodies
ii First Aid Box
19 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
A first aid box has to be provided by the building owner construction site supervisor or brought
personally by the worker under the supervision of the responsible person
65 Training Programme
The management shall conduct periodic training programmes for the workers with regards to work
safety on aspects including the following -
i Dangers of electrical work being undertaken and how to control those dangers
ii The safety regulations set for the work place and
iii First aid procedures
66 Fire Prevention
Fire Extinguisher A suitable functioning fire extinguisher to control fires has to be made available at
the work place at all times
67 Competent Person
The Electricity Regulations 1994 require that all electrical work has to be undertaken by or under the
direct supervision of a competent person registered with the Energy Commission Besides that the
electrical contractor undertaking the electrical work has also to be registered with the Energy
Commission The installation owner thus has to ensure that the appointed electrical contractor is
registered with the Energy Commission and that the registration is still valid
INSTALLATION CIRCUITS AND SYSTEMS1 Block diagrams
These show using squares rectangles etc the sequence of a system without too much technical detail
eg Figures 1517 and 1526
2 Layout diagrams
These are very similar to block diagrams but they indicate more technical detail and tend to show
items in their correct geographical location (eg Figures 1518 and 1519)
3 Circuitschematic
These show how a circuit functions and takes no account of exact locations of terminals or equipment
(eg Figures 1528 1529 1532 1534 etc)
4 Wiring diagram
These indicate how a circuit or system is physically wired (eg Figures 152 154 156 etc)
Most induction motors are started directly on line but when very large motors are started that way
they cause a disturbance of voltage on the supply lines due to large starting current surges To limit the
starting current surge large induction motors are started at reduced voltage and then have full supply
voltage reconnected when they run up to near rotated speed Two methods are used for reduction of
starting voltage are star delta starting and auto transformer stating
20 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Working Principal of Star-Delta Starter
This is the reduced voltage starting method Voltage reduction during star-delta starting is achieved by
physically reconfiguring the motor windings as illustrated in the figure below During starting the
motor windings are connected in star configuration and this reduces the voltage across each winding 3
This also reduces the torque by a factor of three After a period of time the winding are reconfigured as
delta and the motor runs normally
StarDelta starters are probably the most common reduced voltage starters They are used in
an attempt to reduce the start current applied to the motor during start as a means of reducing the
disturbances and interference on the electrical supply
Traditionally in many supply regions there has been a requirement to fit a reduced voltage
starter on all motors greater than 5HP (4KW) The StarDelta (or WyeDelta) starter is one of the
lowest cost electromechanical reduced voltage starters that can be applied
The StarDelta starter is manufactured from three contactors a timer and a thermal overload
The contactors are smaller than the single contactor used in a Direct on Line starter as they are
controlling winding currents only The currents through the winding are 1root 3 (58) of the
current in the line
There are two contactors that are close during run often referred to as the main contractor and
the delta contactor These are AC3 rated at 58 of the current rating of the motor The third
contactor is the star contactor and that only carries star current while the motor is connected in star
The current in star is one third of the current in delta so this contactor can be AC3 rated at one
third (33) of the motor rating
Star-delta Starter Consists following units
1) Contactors (Main star and delta contactors) 3 Norsquos (For Open State Starter) or 4 Norsquos (Close
Transient Starter)
2) Time relay (pull-in delayed) 1 No
3) Three-pole thermal over current release 1No
4) Fuse elements or automatic cut-outs for the main circuit 3 Nos
5) Fuse element or automatic cut-out for the control circuit 1No
Power Circuit of Star Delta Starter
1 The main circuit breaker serves as the main power supply switch that supplies electricity to the
power circuit
2 The main contactor connects the reference source voltage R Y B to the primary terminal of the
motor U1 V1 W1
21 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
3 In operation the Main Contactor (KM3) and the Star Contactor (KM1) are closed initially and
then after a period of time the star contactor is opened and then the delta contactor (KM2) is
closed The control of the contactors is by the timer (K1T) built into the starter The Star and Delta
are electrically interlocked and preferably mechanically interlocked as well In effect there are
four states
4 The star contactor serves to initially short the secondary terminal of the motor U2 V2 W2 for the
start sequence during the initial run of the motor from standstill This provides one third of DOL
current to the motor thus reducing the high inrush current inherent with large capacity motors at
startup
5 Controlling the interchanging star connection and delta connection of an AC induction motor is
achieved by means of a star delta or wye delta control circuit The control circuit consists of push
button switches auxiliary contacts and a timer
Control Circuit of Star-Delta Starter (Open Transition)
1 The ON push button starts the circuit by initially energizing Star Contactor Coil (KM1) of star
circuit and Timer Coil (KT) circuit
2 When Star Contactor Coil (KM1) energized Star Main and Auxiliary contactor change its
position from NO to NC
3 When Star Auxiliary Contactor (1)( which is placed on Main Contactor coil circuit )became
NO to NC itrsquos complete The Circuit of Main contactor Coil (KM3) so Main Contactor Coil
energized and Main Contactorrsquos Main and Auxiliary Contactor Change its Position from NO
To NC This sequence happens in a friction of time
4 After pushing the ON push button switch the auxiliary contact of the main contactor coil (2)
which is connected in parallel across the ON push button will become NO to NC thereby
providing a latch to hold the main contactor coil activated which eventually maintains the
control circuit active even after releasing the ON push button switch
5 When Star Main Contactor (KM1) close its connect Motor connects on STAR and itrsquos
connected in STAR until Time Delay Auxiliary contact KT (3) become NC to NO
6 Once the time delay is reached its specified Time the timerrsquos auxiliary contacts (KT)(3) in
Star Coil circuit will change its position from NC to NO and at the Same Time Auxiliary
contactor (KT) in Delta Coil Circuit(4) change its Position from NO To NC so Delta coil
energized and Delta Main Contactor becomes NO To NC Now Motor terminal connection
change from star to delta connection
7 A normally close auxiliary contact from both star and delta contactors (5amp6)are also placed
opposite of both star and delta contactor coils these interlock contacts serves as safety
switches to prevent simultaneous activation of both star and delta contactor coils so that one
22 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
cannot be activated without the other deactivated first Thus the delta contactor coil cannot be
active when the star contactor coil is active and similarly the star contactor coil cannot also
be active while the delta contactor coil is active
8 The control circuit above also provides two interrupting contacts to shutdown the motor
The OFF push button switch break the control circuit and the motor when necessary The
thermal overload contact is a protective device which automatically opens the STOP Control
circuit in case when motor overload current is detected by the thermal overload relay this is to
prevent burning of the motor in case of excessive load beyond the rated capacity of the motor
is detected by the thermal overload relay
9 At some point during starting it is necessary to change from a star connected winding to a
delta connected winding Power and control circuits can be arranged to this in one of two
ways ndash open transition or closed transition
What is Open or Closed Transition Starting
(1) Open Transition Starters
Discuss mention above is called open transition switching because there is an open state between
the star state and the delta state
In open transition the power is disconnected from the motor while the winding are reconfigured via
external switching
When a motor is driven by the supply either at full speed or at part speed there is a rotating
magnetic field in the stator This field is rotating at line frequency The flux from the stator field
induces a current in the rotor and this in turn results in a rotor magnetic field
When the motor is disconnected from the supply (open transition) there is a spinning rotor within
the stator and the rotor has a magnetic field Due to the low impedance of the rotor circuit the time
constant is quite long and the action of the spinning rotor field within the stator is that of a
generator which generates voltage at a frequency determined by the speed of the rotor When the
motor is reconnected to the supply it is reclosing onto an unsynchronized generator and this result
in a very high current and torque transient The magnitude of the transient is dependent on the
phase relationship between the generated voltage and the line voltage at the point of closure can
be much higher than DOL current and torque and can result in electrical and mechanical damage
Open transition starting is the easiest to implement in terms or cost and circuitry and if the timing
of the changeover is good this method can work well In practice though it is difficult to set the
necessary timing to operate correctly and disconnectionreconnection of the supply can cause
significant voltagecurrent transients
In Open transition there are Four states
23 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 OFF State All Contactors are open
2 Star State The Main [KM3] and the Star [KM1] contactors are closed and the delta [KM2]
contactor is open The motor is connected in star and will produce one third of DOL torque at one
third of DOL current
3 Open State This type of operation is called open transition switching because there is an
open state between the star state and the delta state The Main contractor is closed and the Delta
and Star contactors are open There is voltage on one end of the motor windings but the other end
is open so no current can flow The motor has a spinning rotor and behaves like a generator
4 Delta State The Main and the Delta contactors are closed The Star contactor is open The
motor is connected to full line voltage and full power and torque are available
(2) Closed Transition StarDelta Starter
There is a technique to reduce the magnitude of the switching transients This requires the use of a
fourth contactor and a set of three resistors The resistors must be sized such that considerable
current is able to flow in the motor windings while they are in circuit
The auxiliary contactor and resistors are connected across the delta contactor In operation just
before the star contactor opens the auxiliary contactor closes resulting in current flow via the
resistors into the star connection Once the star contactor opens current is able to flow round
through the motor windings to the supply via the resistors These resistors are then shorted by the
delta contactor If the resistance of the resistors is too high they will not swamp the voltage
generated by the motor and will serve no purpose
In closed transition the power is maintained to the motor at all time This is achieved by
introducing resistors to take up the current flow during the winding changeover A fourth
contractor is required to place the resistor in circuit before opening the star contactor and then
removing the resistors once the delta contactor is closed These resistors need to be sized to carry
the motor current In addition to requiring more switching devices the control circuit is more
complicated due to the need to carry out resistor switching
In Close transition there are Four states
1 OFF State All Contactors are open
2 Star State The Main [KM3] and the Star [KM1] contactors are closed and the delta [KM2]
contactor is open The motor is connected in star and will produce one third of DOL torque at one
third of DOL current
Star Transition State The motor is connected in star and the resistors are connected across the
delta contactor via the aux [KM4] contactor
24 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Closed Transition State The Main [KM3] contactor is closed and the Delta [KM2] and Star
[KM1] contactors are open Current flows through the motor windings and the transition resistors
via KM4
Delta State The Main and the Delta contactors are closed The transition resistors are shorted out
The Star contactor is open The motor is connected to full line voltage and full power and torque
are available
Effect of Transient in Starter (Open Transient starter)
It is Important the pause between star contactor switch off and Delta contactor switch is on correct
This is because Star contactor must be reliably disconnected before Delta contactor is activated It
is also important that the switch over pause is not too long
For 415v Star Connection voltage is effectively reduced to 58 or 240v The equivalent of 33
that is obtained with Direct Online (DOL) starting
If Star connection has sufficient torque to run up to 75 or 80 of full load speed then the motor
can be connected in Delta mode
When connected to Delta configuration the phase voltage increases by a ratio of V3 or 173 The
phase currents increase by the same ratio The line current increases three times its value in star
connection
During transition period of switchover the motor must be free running with little deceleration
While this is happening ldquoCoastingrdquo it may generate a voltage of its own and on connection to the
supply this voltage can randomly add to or subtract from the applied line voltage This is known as
transient current Only lasting a few milliseconds it causes voltage surges and spikes Known as
a changeover transient
Size of each part of Star-Delta starter
(1) Size of Over Load Relay
For a star-delta starter there is a possibility to place the overload protection in two positions in the
line or in the windings
Overload Relay in Line
In the line is the same as just putting the overload before the motor as with a DOL starter
The rating of Overload (In Line) = FLC of Motor
Disadvantage If the overload is set to FLC then it is not protecting the motor while it is in delta
(setting is x1732 too high)
Overload Relay in Winding
25 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
In the windings means that the overload is placed after the point where the wiring to the contactors
are split into main and delta The overload then always measures the current inside the windings
The setting of Overload Relay (In Winding) =058 X FLC (line current)
Disadvantage We must use separate short circuit and overload protections
(2) Size of Main and Delta Contractor
1 There are two contactors that are close during run often referred to as the main contractor and
the delta contactor These are AC3 rated at 58 of the current rating of the motor
Size of Main Contactor= IFL x 058
(3) Size of Star Contractor
The third contactor is the star contactor and that only carries star current while the motor is
connected in star The current in star is 1 radic3= (58) of the current in delta so this contactor can
be AC3 rated at one third (33) of the motor rating
Size of Star Contactor= IFL x 033
Motor Starting Characteristics of Star-Delta Starter
Available starting current 33 Full Load Current
Peak starting current 13 to 26 Full Load Current
Peak starting torque 33 Full Load Torque
Advantages of Star-Delta starter
The operation of the star-delta method is simple and rugged
It is relatively cheap compared to other reduced voltage methods
Good TorqueCurrent Performance
It draws 2 times starting current of the full load ampere of the motor connected
Disadvantages of Star-Delta starter
Low Starting Torque (Torque = (Square of Voltage) is also reduce)
Break In Supply ndash Possible Transients
Six Terminal Motor Required (Delta Connected)
It requires 2 set of cables from starter to motor
It provides only 33 starting torque and if the load connected to the subject motor requires higher
starting torque at the time of starting than very heavy transients and stresses are produced while
changing from star to delta connections and because of these transients and stresses many
electrical and mechanical break-down occurs
26 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
In this method of starting initially motor is connected in star and then after change over the motor
is connected in delta The delta of motor is formed in starter and not on motor terminals
High transmission and current peaks When starting up pumps and fans for example the load
torque is low at the beginning of the start and increases with the square of the speed When
reaching approx 80-85 of the motor rated speed the load torque is equal to the motor torque and
the acceleration ceases To reach the rated speed a switch over to delta position is necessary and
this will very often result in high transmission and current peaks In some cases the current peak
can reach a value that is even bigger than for a DOL start
Applications with a load torque higher than 50 of the motor rated torque will not be able to start
using the start-delta starter
Low Starting Torque The star-delta (wye-delta) starting method controls whether the lead
connections from the motor are configured in a star or delta electrical connection The initial
connection should be in the star pattern that results in a reduction of the line voltage by a factor of
1radic3 (577) to the motor and the current is reduced to 13 of the current at full voltage but the
starting torque is also reduced 13 to 15 of the DOL starting torque
The transition from star to delta transition usually occurs once nominal speed is reached but is
sometimes performed as low as 50 of nominal speed which make transient Sparks
Features of star-delta starting
1 For low- to high-power three-phase motors
2 Reduced starting current
3 Six connection cables
4 Reduced starting torque
5 Current peak on changeover from star to delta
6 Mechanical load on changeover from star to delta
Application of Star-Delta Starter
The star-delta method is usually only applied to low to medium voltage and light starting
Torque motors
The received starting current is about 30 of the starting current during direct on line start and the
starting torque is reduced to about 25 of the torque available at a DOL start This starting
method only works when the application is light loaded during the start If the motor is too heavily
27 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
loaded there will not be enough torque to accelerate the motor up to speed before switching over
to the delta position
LESSON 1 WIRING SYSTEM OF SINGLE PHASE DISTRIBUTION BOARD
Introduction
28 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
29 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
30 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
31 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 2 WIRING SYSTEM OF SINGLE PHASE LIGHTING CIRCUIT Introduction
Objectives
1 Identify component and the specification
2 Wire component according to the schematic diagram
3 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Wiring bay Perforated metal 180 cm x 180 cm 1
2 Cut out fuse 63 A 240 V 1
3 Neutral link 1
4 Single pole one way switch cw
switch box
5A 240Vac 4
5 single pole two way switch cw
switch box
5A 240Vac 2
6 RCCB In = 40 A Tripping current
100mA240 Vac 50 Hz
1
7 Main switch 32 A 240V 1
8 kWatthour meter 40 A 240 Vac 1
9 Single pole MCB 6A 240 Vac 1
10 Self tapping Wood screw As required
11 DIN rail 35 mm width As required
32 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
12 PVC trunking 50 mm x 50 mm As required
13 Terminal blocks 5 A As required
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
1 One way switch to control one lamp
2 One way switch to control two lamps
3 Two of two way switch to control one lamp
4 Two of single pole two way switch and one of an intermediate switch to control one
lamp
5 One unit of ceiling fan and fan regulator to be controlled by one way switch
4 Test the functionality of completed project
LESSON 3ndash WIRING SYSTEM OF SINGLE PHASE POWER CIRCUIT Introduction
33 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
34 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify types of component and its specification
2 Wire component according to the schematic diagram given
3 Test the functionality of the circuit dead circuit test life circuit test
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board Perforated Metal 1
2 kWh meter 240 V 40 A 1
3 Socket outlet 13A 240Vac 4
4 RCCB 40A Trip Amps
30mA240 Vac
1
5 3 pin socket 240Vac 13A 4
6 Single pole MCB 20A 240 V 2
7 DOL starter 1 kW 240Vac 2
8 1 phase induction motor 2Hp 240 Vac 1
9 Cooker control unit 4kW 240Vac 1
10 Water heater point 4kW 240 Vac 1
11 DIN rail 35 mm As required
12 PVC casing 20mm As required
13 Flexible wires 05 mm As required
14 Terminal block 10 A As required
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Wire two unit of 13 A socket outlet in radial circuit
3 Wire four units of 13 A socket outlet in ring circuit
4 Wire one unit DOL starter for air-conditioner point
5 Wire one unit of cooker control unit point
6 Wire one unit of water heater point
7 Test the functionality of each component by using mmeter or power supply whichever
applicable
8 Wire component according to circuit diagram
9 Test the functionality of completed project dead circuit test life circuit test
Note
35 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Ensure that the correct rating of protection device and size of wire used
LESSON 4ndash CONDUIT BENDING AND TRUNKING FABRICATION TECHNIQUE
Common fitting used in an industrial wiring
Cutting and threading the condute
36 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
37 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
38 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify conduit fitting and the specification
2 Measure and Cut steel conduit according to specified dimension
3 Bend and fabricate conduit at 45 90 according to layout diagram
4 Wire component according to the schematic diagram
5 Test the functionality of the circuit
39 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Conduit Bender Oslash 19 mm ( frac34 ldquo) 1
2 Measuring Tape 3 metre 1
3 Hacksaw frame and blade 30cm 1
4 Conduit cutter 1
5 Pipe Vise 1
6 Pipe Wrench 1
7 Ratchet Dies 20 mm 1
8 Metal trunking 50 mm x 50 mm 1
9 GI conduit 20mm 1
10 End box 20 mm 1
11 Flexible wires 05 mm As required
12 Connectors 5 A As required
13 Single core PVC ins Cable 25 mm 2 As required
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Wire two unit of 13 A socket outlet in radial circuit
3 Wire four unit of 13 A socket outlet in ring circuit
4 Wire one unit DOL starter for air-conditioner point
5 Wire one unit of cooker control unit point
6 Wire one unit of water heater point
7 Test the functionality of each component by using multimeter or power supply whichever
applicable
8 Wire component according to circuit diagram
9 Test the functionality of completed project
Note
Ensure that the rating of protection device and size of wire
K prior to 31 March
2004 (BS 7671)
(formerly)
bare conductor
sleeved at terminations (formerly)
40 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 5 ndashWIRING SYSTEM OF 1 Oslash LIGHTING AND POWER CIRCUIT
POWER CIRCUITSa Radial circuits
Radial circuits are arranged in the same way as item 1 above in lighting layouts in that each socket
outlet is supplied via the previous one
Points to note
1 The number of socket outlets complying with BS 1363 is unlimited for a floor area of up to 50m 2 if
the circuit protection is a 30 A or 32 A cartridge fuse or circuit breaker the cable being 4 mm PVC
copper or 25 mm2 mineral insulated (mi)
2 The number of socket outlets is unlimited for a floor area up to 20 m 2 with any type of circuit
protection of 20 A using 25 mm2 PVC copper cable or 15 mm2 mi
3 The total number of fused spurs is unlimited
b ring final circuits
These circuits are the same as radial circuits except that the final socket outlet is wired back to the
supply position In effect any outlet is supplied from two directions (Fig 152)
Points to note
1 Every twin-socket outlet counts as two single-socket outlets
2 The number of non-fused spurs must not exceed the total number of points on the ring Fig 158
shows seven points on the ring and five spurs
3 The fuse rating of a fused spur box must not exceed 13 A and the current rating of all points supplied
by the fused spur must not exceed 13 A
4 Non-fused spurs must supply no more than one single or one double socket on the ring Fig 158
shows seven points on the ring and five spurs rating of all points supplied by the fused spur must not
exceed 13 A or one stationary appliance
CapacityMain conductor size
copper (mm2)
Earth conductor
size (mm2)
Circuit breaker
capacity (A)
Up to 600 W 15 15 6
600ndash1200 W 1525 15 10
1200ndash1800 W 254 25 16
41 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Ring circuit
(floor area 100 m2)25 15 3032
A2 radial circuit
(floor area 75 m2)40 25 3032
A3 radial circuit
(floor area 50 m2)25 15 20
Air conditioner (15 tonne) 60 60 3032
Cooker 60 60 3032
Water heater 40 40 20
Objectives
1 Identify component and the specification
2 Wire component according to the schematic diagram
3 Test the functionality of the circuit
42 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board Perforated 1
2 Cut out fuse and neutral link 60A 240V 1each
3 kWh meter 240V 40A 1
4 Switched Socket outlet 13A 240Vac 4
5 Single pole two way switch cw switch
box
5A 240Vac 2
6 RCCB ELCB 63 A Tripping current 100mA
415 Vac
1
7 3 pin plug 240Vac 13A 4
8 Single pole MCB 20 A 2
9 Single pole MCB 6A 1
10 Single pole MCB 20A 2
11 DOL starter 240Vac 2
12 1 phase induction motor 2hp 240 Vac 1
13 Self tapping Wood screw As required
14 DIN rail Stainless steel allum35 mm As required
15 PVC pipe 20mm dia As required
16 End box 20 mm dia 4
17 Flexible wires 05 mm 2 As required
18 Connectors 5 A As required
Procedures
43 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
4 Test the functionality of completed project
LESSON 6 ndash WIRING SYSTEM OF 3 Oslash DISTRIBUTION BOARD
Introduction
44 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
45 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
46 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
47 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
48 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify each component and the specification
2 Wire component according to the schematic diagram given
3 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting Board 450 x 600 mm Perforated metal 1
2 5 pin round socket and plug 415V ac 32A 1
3 Cut out fuse 60 A 3
4 Neutral link 1
5 kWatt hour meter 415V 60A 1
6 ELCB RCCB 3P+N In=63A415 Vac I trip= 300mA 1
7 ELCB RCCB 3P+N In=63A415 Vac I trip= 30mA 1
8 Single pole MCB 6A 240 V 3
9 Single pole MCB 20A 240 V 3
10 DOL starter 20 A 240Vac 2
11 Socket outlet 15 A 240 Vac 1
12 Switched Socket outlet 13 A 240 Vac 3
13 Led indicating light 5A 240 Vac 3
14 Single pole 4 gang 1 way switch 5A 240 Vac 2
15 Single pole 2 way switch 5A 240 Vac 2
16 1 phase induction motor 1 kW 240Vac 1
17 Metal trunking 30 mm x30 mm As required
18 Self tapping Wood screw 4 mm x 20 mm As required
19 DIN rail 25 mm x 1mm
20 GI steel rigid conduit 20mm As required
21 Flexible conduit 20mm As required
22 End box 20 mm 4
23 Flexible wires 05 mm 2 As required
24 Single core PVC insulated wire 15 mm 2 As required
25 Single core PVC insulated wires 25 mm 2 As required
26 Terminal block 10 A As required
Procedures
49 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify each components and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
4 Test the functionality of completed project
1 dead circuit test
2 life circuit
Note Proper earthing should be made
50 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 7 ndash WIRING SYSTEM OF THREE PHASE LIGHTING AND POWER CIRCUIT
51 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
52 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify component and the specification
2 Wire component according to the schematic diagram
3 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting bay Board Perforated metal 180 cm x 180 cm 1
2 k Watt hour meter 415V 60A 1
3 MCCB 415V 60A
4 ELCB RCCB In=60A415 Vac I trip=30mA 1
5 5 pin round Socket and
plug
415Vac 32A 4
6 Single pole MCB 6A 1
7 Triple pole MCB 20A 2
8 Triple pole Main switch 60A 1
9 DOL starter 240Vac 2
10 3 phase induction motor 2hp 415 Vac 1
11 1 phase induction motor 1
12 Metal trunking 30 mm x30 mm As required
13 Self tapping Wood screw 4 mm x 20 mm As required
14 DIN rail 25 mm x 1mm
15 GI steel rigid conduit 20mm As required
16 Flexible conduit 20mm As required
17 End box 20 mm 4
18 Flexible wires 05 mm As required
19 Connectors 10 A As required
Procedures
1 Identify each components and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
4 Test the functionality of completed project
1 dead circuit 2 life circuit test
5 Record the current drawn by the load as connected in star and delta
Note Proper earthing should be made
53 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 8 INSPECTION AND TESTING OF ELECTRICAL INSTALLATION
On completion of a wiring installation a number of tests on the installation have to be conducted to
ascertain that the wiring circuits and connected appliances are safe for use Prior to carrying out the
tests an inspection has to be done The results of the inspectionsupervision and test have to be
presented in Form G (as in Appendix IV) and Form H (as in Appendix V)
To have the test certification as in Form H the following tests shall be conducted
i Continuity Test
ii Insulation Resistance Test
iii Polarity Test
iv Earth Electrode Resistance test and
v Residual Current Device Test
1 Continuity Test
There are 3 main types of continuity tests for the final circuits-
i Protection Conductor Continuity Test
ii Final Ring Circuit Conductor Continuity Test
iii Live and Neutral Conductor Continuity Test
a) Protection Conductor Continuity Test
bull To ascertain that all protection conductors are connected in the correct and effective manner
bull Test equipment ndash Multimeter (Ohm range) or Ohm meter
54 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
bull Test Method
1 1048766 Ensure that the main switch RCD and MCB are open circuited (switched off) and all loads
are disconnected
2 1048766 Connected the test leads as in the Figure 81 The meter reading shall be less than 1 Ω
55 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Final Ring Circuit Conductor Continuity Test
bull To ensure that all conductors around the ring circuit have continuity
bull Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
bull Test Method
1 1048766 Disconnect both the supply source live conductors from the MCB the neutral conductor
from the neutral terminals and the earth conductor from the earth terminal in the distribution
fuse box
2 1048766 Connect the test leads as in the Figure 82 (EE)
3 1048766 Repeat the procedure for (L-L) and (N-N)
4 1048766 The meter reading value shall be less than 1 ohm
56 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Live and Neutral Conductor Continuity Test
a To ensure that each conductor in the circuit has continuity
b Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
2 Test Method
1 1048766 Switch off the Main switch RCD and MCB
2 1048766 Disconnect all loads
3 1048766 Switch on all switches in the circuit
4 1048766 Disconnect the fusesfinal circuit breakers and close the circuit
5 1048766 Carry out the test as shown in Figure 83
6 1048766 The meter reading value shall be less than 1Ω
57 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
58 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
CONTINUITY TEST
Insulation Resistance Test
i Ensure that there is no leakage current between phase conductors phase and neutral conductors and
phase conductor and earth
ii Test the strength of the cable insulation
iii Test Equipment ndash Insulation Resistance Tester operating voltage is 250VDC or 500VDC
iv Test Method
1 1048766 Switch off main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
59 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
4 1048766 Carry out test as in the Table below
5 1048766 Meter reading value shall be less than 1 Megaohm
60 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
61 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Insulation resitance test
62 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
INSULATION RESISTANCE TEST BETWEEN CONDUCTORS AND OPPOSITE POLARITY
Polarity Testi Ensure that each fuse or single pole control and protection device is connected only in the phase
conductor
ii Intermediate contact of Edison screw lamp holder is connected to the phase conductor
iii Ensure that phase neutral and earth conductors at socket outlets are connected at the correct
terminals
iv Test Equipment ndash Multimeter (Ohm range) or Ohm meter
v Test Method
1 1048766 Switch off Main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in Figure 85
63 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
5 1048766 Test switches and single phase control devices at the phase conductors
6 1048766 Test socket outlet connection sources
7 1048766 Test Edison screw lamp holder connections
8 1048766 Meter reading value shall be less than 1 Ω
64 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Polarity test
65 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Earth Electrode Resistance Testi To test the earth electrode resistance
ii To ascertain the suitability of the location of the electrode
iii To ensure that the electrode is not buried within the resistance area of another electrode
iv Test equipment ndash Earth Resistance Tester
v Test method -
1 1048766 Terminal rsquoErsquo is connected to the electrode to be tested (green conductor)
2 1048766 Terminal lsquoPrsquo is connected to the potential spike (yellow conductor) at a distance of 10
meters from the earth electrode
3 1048766 Terminal lsquoCrsquo is connected to the current spike (red conductor) at a distance of 20 meters
from the earth electrode
Earth Electrode Resistance Measurement Method (Figure 86)
This test must be repeated at least three times to ensure that the reading is not affected by interacting
earthing regions
i Record the first reading (Z1) Example Z1 = 10 Ω
ii Move the voltage spike to a distance of 6 meters from the original position Record the second
reading (Z2 ) Example Z2 = 10 Ω
iii Move the voltage spike to a distance of 6 meters from the original position Record the third
reading (Z3) Example Z3 = 10 Ω
66 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Residual Current Device Testi Ensure that the residual current device (RCD) trips within the set time on the occurrence of current
leakage to earth
ii Test Equipment ndash RCD Tester RCCB Tester
iii Test Method 1
1 1048766 Use the Trip Test Button
2 1048766 Press the trip button found on the RCD to determine if it trips or otherwise This test would
not be able to determine the sensitivity of the RCD nor the time taken for it to trip
iv Test Method 2
i 1048766 Use a RCD Tester
ii This equipment is equipped with a 13A plug which can be connected to a 13A socket outlet
Select the RCD sensitivity to be the same as the sensitivity of the RCD to be tested to
determine if the RCD can trip The time to trip shall not exceed 40 mS
iii 1048766 Test method ndash
a) Position the selection switch in accordance with the sensitivity of the RCD used
Example 100 mA 01 A
b) Position the operations switch to lsquoNo Triprsquo (frac12 Rated mA = 50) connect the 3 pin plug to
the 13A socket outlet
67 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
c) Switch on the 13A socket outlet ndash ensure that the P-N and P-E lights light up
This shows that the polarity is correct (Note if both the lights as above do not light up the test cannot
be continued)
d) Press the test button ndash the reading shows less than 200 mS and simultaneously the lsquotestrsquo light lights
up and the P-N and P-E lights do not light up At that instant the RCD will not trip
e) Move the selection switch to 180o (+ve wave) ndash repeat steps (d) and (e) Move the operations
switch to lsquoTriprsquo (Rated mA = 100)
g) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200mS
h) Move the selection switch to 0o (-ve wave)
i) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
j) The above test is repeated until a near correct reading is obtained
k) Record the test results
l) Change the operations switch to lsquoFast Triprsquo and press the test button ndash RCD will trip within a
time not exceeding 40 millisecond
m) Repeat a number of times at 0o or 180o
On completion of a wiring installation a number of tests on the installation have to be conducted to
ascertain that the wiring circuits and connected appliances are safe for use Prior to carrying out the
tests an inspection has to be done the following tests shall be conducted
i Continuity Test
ii Insulation Resistance Test
iii Polarity Test
iv Earth Electrode Resistance test and
v Residual Current Device Test
821 Continuity Test
There are 3 main types of continuity tests for the final circuits-
i Protection Conductor Continuity Test
ii Final Ring Circuit Conductor Continuity Test
68 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
iii Live and Neutral Conductor Continuity Test
a) Protection Conductor Continuity Test
bull To ascertain that all protection conductors are connected in the correct and effective manner
bull Test equipment ndash Multimeter (Ohm range) or Ohm meter
bull Test Method
1 1048766 Ensure that the main switch RCD and MCB are open circuited (switched off) and all loads are
disconnected
2 1048766 Connected the test leads as in the Figure 81
3 1048766 The meter reading shall be less than 1 Ω
Final Ring Circuit Conductor Continuity Test
bull To ensure that all conductors around the ring circuit have continuity
bull Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
bull Test Method
1 1048766 Disconnect both the supply source live conductors from the MCB the neutral conductor
from the neutral terminals and the earth conductor from the earth terminal in the distribution
fuse box
2 1048766 Connect the test leads as in the Figure 82 (EE)
3 1048766 Repeat the procedure for (L-L) and (N-N)
4 1048766 The meter reading value shall be less than 1 ohm Figure 82 - Final Ring Circuit Conductor
Continuity Test Ohm Meter
Disconnect both the supply source cables from mcbfuse
Take readings at earth conductors of both sources and note resistance readings
Live and Neutral Conductor Continuity Test
1 To ensure that each conductor in the circuit has continuity
2 Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
3 Test Method
1 1048766 Switch off the Main switch RCD and MCB
2 1048766 Disconnect all loads
3 1048766 Switch on all switches in the circuit
4 1048766 Disconnect the fusesfinal circuit breakers and close the circuit
5 1048766 Carry out the test as shown in Figure 83
6 1048766 The meter reading value shall be less than 1 ohm Figure 83 - Live and Neutral
Conductor Continuity Test Ohm Meter
Insulation Resistance Test
69 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
i Ensure that there is no leakage current between phase conductors phase and neutral conductors and
phase conductor and earth
ii Test the strength of the cable insulation
iii Test Equipment ndash Insulation Resistance Tester Operating voltage is 250VDC or 500VDC
iv Test Method
1 1048766 Switch off main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in the Table below
5 1048766 Meter reading value shall be less than 1 Megaohm
Polarity Test
i Ensure that each fuse or single pole control and protection device is connected only in the phase
conductor
ii Intermediate contact of Edison screw lamp holder is connected to the phase conductor
iii Ensure that phase neutral and earth conductors at socket outlets are connected at the correct
terminals
iv Test Equipment ndash Multimeter (Ohm range) or Ohm meter
v Test Method
1 1048766 Switch off Main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in Figure 85
5 1048766 Test switches and single phase control devices at the phase conductors
6 1048766 Test socket outlet connection sources
7 1048766 Test Edison screw lamp holder connections
8 1048766 Meter reading value shall be less than 1 Ω
Earth Electrode Resistance Test
i To test the earth electrode resistance
70 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
ii To ascertain the suitability of the location of the electrode
iii To ensure that the electrode is not buried within the resistance area of another electrode
iv Test equipment ndash Earth Resistance Tester
v Test method -
1 1048766 Terminal rsquoErsquo is connected to the electrode to be tested (green conductor)
2 1048766 Terminal lsquoPrsquo is connected to the potential spike (yellow conductor) at a distance of 10
meters from the earth electrode
3 1048766 Terminal lsquoCrsquo is connected to the current spike (red conductor) at a distance of 20 meters
from the earth electrode E P C Electrode 10 meter 10 meter
Figure 86 ndash Earth Electrode Resistance Measurement Test Equipment
Earth Electrode Resistance Measurement Method (Figure 86)
This test must be repeated at least three times to ensure that the reading is not affected by interacting
earthing regions
i Record the first reading (Z1) Example Z1 = 10 Ω
ii Move the voltage spike to a distance of 6 meters from the original position Record the second
reading (Z2) Example Z2 = 10 Ω
iii Move the voltage spike to a distance of 6 meters from the original position Record the third
reading (Z3)
Example Z3 = 10 Ω
Residual Current Device Test
71 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
i Ensure that the residual current device (RCD) trips within the set time on the occurrence of current
leakage to earth
ii Test Equipment ndash RCD Tester RCCB Tester
iii Test Method 1
1 1048766 Use the Trip Test Button
2 1048766 Press the trip button found on the RCD to determine if it trips or otherwise This test would
not be able to determine the sensitivity of the RCD nor the time taken for it to trip
iv Test Method 2
1048766 Use a RCD Tester
This equipment is equipped with a 13A plug which can be connected to a 13A socket outlet Select the
RCD sensitivity to be the same as the sensitivity of the RCD to be tested to determine if the RCD can
trip The time to trip shall not exceed 40 mS
1048766 Test method ndash
a) Position the selection switch in accordance with the sensitivity of the RCD used
Example 100 mA 01 A
b) Position the operations switch to lsquoNo Triprsquo (frac12 Rated mA = 50) connect the 3 pin plug to
the 13A socket outlet
c) Switch on the 13A socket outlet ndash ensure that the P-N and P-E lights light up This shows that
the polarity is correct (Note if both the lights as above do not light up the test cannot be
continued)
d) Press the test button ndash the reading shows less than 200 millisecond and simultaneously the
lsquotestrsquo light lights up and the P-N and P-E lights do not light up At that instant the RCD will
not trip
e) Move the selection switch to 180o (+ve wave) ndash repeat steps (d) and (e) = 100)
f) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
g) Move the selection switch to 0o (-ve wave)
h) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
i) The above test is repeated until a near correct reading is obtained
j) Record the test results
k) Change the operations switch to lsquoFast Triprsquo and press the test button ndash RCD will trip within a
time not exceeding 40 mS
l) Repeat a number of times at 0o or 180o
72 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 9 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (DC)
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
73 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Start stop button 240Vac 5A 2
9 Filament lamp (Bulb ) 240Vac 40W 3
10 Overload Relay 415V 20A 3
11 Three phase induction motor 5 hp 3
12 Single phase step down transformer 2500VA 1
13 Single core PVC insulated Cable 1mm 2 As required
14 Single core PVC insulated Cable 25mm 2 As required
15 DIN rail 35 mm As required
16 PVC type Cable tray 50 mm x 50 mm As required
17 Cable ties 4 ldquo As required
18 Flexible wires 05 mm As required
19 PVC Connectors 5 A amp 20 A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the schematic
diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a optional exercise
i Simple DOL starter
ii Forward reverse DOL starter
iii Forward Reverse Dahlander motor
iv Three motors operated in sequence by DOL starter operated by manual push
button or time delay relay
74 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
a One loop per-cycle
b Continuous operation in a loop
c optional circuit design to represent the same task
v Only one out of three motors to be operated at a time (quiz)
4 Test the functionality of completed project
LESSON 10 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (AC)
75 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 1
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Lamp point 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
76 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
11 Overload Relay 415V 20A 3
12 Three phase induction
motor
5 hp 3
13 Single core PVC insulated
Cable
1mm 2 As required
14 Single core PVC insulated
Cable
25mm 2 As required
15 DIN rail 35 mm As required
16 PVC type Cable tray 50 mm x 50 mm As required
17 Cable ties 4 ldquo As required
18 Flexible wires 05 mm As required
19 PVC Connectors 5 A amp 20 A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the
schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram optional exercise
4 Simple DOL starter
5 Forward reverse DOL starter
6 Test the functionality of completed project
77 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 1
78 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
cm
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Indicating light 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
11 Overload Relay 415V 20A 3
12 Three phase induction motor 5 hp 3
13 Single phase step down
transformer
2500VA 1
14 Single core PVC insulated
Cable
1mm 2 As required
15 Single core PVC insulated
Cable
25mm 2 As required
16 DIN rail 35 mm As required
17 PVC type Cable tray 50 mm x 50 mm As required
18 Cable ties 4 ldquo As required
19 Flexible wires 05 mm As required
20 PVC Connectors 5 A amp 20 A 240 V As required
21 Single pole MCB 6A 240 V 1
22 Single pole MCB 2A 240 V 1
23 Triple pole MCB 20A 415 V 1
24 Mounting board 30 cm x 40 cm x 3
cm
1
25 Relay cw 11 pin socket 10 A 240 Vac 2
26 Time delay relay 10 A 240 Vac 3
27 Triple pole Contactor 20A 240Vac 3
28 Batten type Lamp holder 240Vac 10 A 3
29 Start stop button 240Vac 10A 2
30 Indicating light (Bulb ) 240Vac 25W 3
31 Overload Relay 415V 20A 1
32 Three phase dahlander type
induction motor
5 hp 1
33 Single phase step down
transformer
24024Vac
2500VA
1
79 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
34 Single core PVC insulated
Cable
1mm 2 As required
35 Single core PVC insulated
Cable
25mm 2 As required
36 DIN rail 35 mm As required
37 PVC type Cable tray 50 mm x 50 mm As required
38 Cable ties 4 ldquo As required
39 Flexible wires 075 mm As required
40 PVC Connectors 5 A amp 20 A 240 V As required
41 Terminal block 20A 240Vac As required
Procedures
5 Identify each component according to specification and quantity required from the schematic
diagram attached
6 Test the functionality of each component by using multi-meter or power supply whichever
applicable
7 Wire component according to circuit diagram
8 Three motors operated in sequence by DOL starter operated by manual push button or time
delay relay
a One loop per-cycle
b Continuous operation in a loop
c optional circuit design to represent the same task
d Only one out of three motors to be operated at a time (quiz)
9 Test the functionality of completed project
80 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
BASIC DESIGN INDUSTRIAL MOTOR CONTROL (SEQUENCE CONTROL)
THREE PHASE INDUCTION MOTOR OPERATED IN SEQUENCE BY DIRECT ON LINE
STARTER
LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
81 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
82 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Lcd lamp indicator 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
11 Overload Relay 415V 20A 3
12 Three phase induction motor 5 hp 3
13 Single phase step down transformer 2500VA 1
14 Single core PVC insulated Cable 1mm 2 As required
15 Single core PVC insulated Cable 25mm 2 As required
16 DIN rail 35 mm As required
17 PVC type Cable tray 50 mm x 50 mm As required
18 Cable ties 4 ldquo As required
19 Flexible wires 1 mm Oslash As required
20 PVC Terminal block 10A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the schematic
diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a optional exercise
i Forward Reverse dahlander motor
4 Test the functionality of completed project
83 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
THREE PHASE DAHLANDER TYPE INDUCTION MOTOR OPERATED FORWARD AND
REVERSE OPERATION BY DIRECT ON LINE STARTER
84 ndash 99EASYTECH ENTERPRISE
LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
Introduction
If a motors windings are connected in the star configuration any two phases will be in series across
the supply and hence the line current will be smaller(by 577) than if the windings were connected in
the delta arrangement
Hence larger-type motors with heavy starting currents are first connected in star and then when the
starting currents fall in delta This of course means that all six of the ends of the windings must be
brought to terminations outside the casing (Fig 833)
EZTECH
EZTECH ELECTRICAL INSTALLATION GUIDE
The automatic version of this starter incorporates a timing relay which automatically changes the
connections from star to delta Figs 834 and 835 show the wiring and schematic diagrams for a star
delta starter
Objectives
1 Identify component and the specification
2 Design forward reverse star delta starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
2 ndash 99EASYTECH ENTERPRISE
REV -C
LEGENDMCCB Moulded Case Circuit BreakerTOR Thermal Over Load RelayFOW-C Mains Forward ContactorREV-C Mains Reverse ContactorDC Delta ContactorSC Star ContactorS-SW Mains Selector Switch
SC
V2
W2
U2
DC
V1
W1
U1
TOR
TOR
FOW-C
30A MCCB
TOR
MAIN CIRCUIT FORWARD REVERSE STAR DELTA
RYBN S
-SW
3 PHASEINDUCTION MOTOR
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Relay 10 A 240V 3
5 Triple pole Contactor
6 cw NO NC auxiliary contact
240Vac 20 A 4
7 Overload Relay 415 V 1
8 LED indicator 240vac 5 A 4
9 Start stop button 240Vac 5A 2
10 DIN rail 35 mm As required
11 Flexible wires 1 mm As required
12 Single core PVC insulated
wire
25 mm As required
13 Terminal block 20 A As required
14 Squirrel cage motor 5kW 1
15 5 pin plug and socket 415V 20A 1
16 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
3 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
a Manual star delta
b Manual Forward reverse star delta starter
c Automatic star delta starter
d Automatic Forward reverse star delta starter
4 Test the functionality of completed project
4 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
Objectives
1 Identify component and the specification
2 Design auto transformer starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
5 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Autotransformer starter is used to start a 3 phase induction motor that has a rating between 10 to 15 hp
6 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Autotransformer set 10Kw 415 V 50 Hz 1
5 Triple pole Contactor 240Vac 4
6 Batten type Lamp holder 240 Vac 105 A 4
7 Start stop button 240Vac 10A 4
8 Filament lamp (Bulb ) 240Vac 40W 4
9 DIN rail 35 mm As required
10 Flexible wires 1 mm As required
7 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
11 Single core PVC insulated
wire
25 mm As required
12 Terminal block 20 A As required
13 Squirrel cage motor 10kW 1
14 5 pin plug and socket 415V 20A 1
15 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a open transient autotransformer starter
b close transient autotransformer starter
c Forward reverse autotransformer starter
4 Test the functionality of completed project
8 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
Objectives
1 Identify component and the specification
2 Design rotor resistance starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
9 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Rotor Resistor set 10kW 1
5 Triple pole Contactor 240Vac 20A 4
6 Indicating light 240vac 5 A 4
7 Start stop push button 240Vac 5A 4
8 DIN rail 35 mm As required
9 Flexible wires 1 mm 2 As required
10 Single core PVC insulated wire 25 mm 2 As required
11 Terminal block 20 A As required
12 Slip Ring motor 10kW 1
13 5 pin round 3 phase socket 415V 20A 1
14 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
10 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
4 Test the functionality of completed project
a Dead circuit test b Life circuit test
5 Measure starting and running Amps
LESSON 16
TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
An installation in general will suffer damage
Damage usually occurs on the electric motor control as follows
1 Damage to the main circuit
2 Damage to the control circuit
The cause of the damage
i Overcurrent overload short circuit
ii Leakage current to ground
iii Equipment malfunction
iv The main control circuit
a Trip of main circuit protection devices fire
b Defect of motor terminal such as short circuit fire loose
v The control circuit is not functioning -
a contactor relay relay time overload relay does not work damaged burned
b Loose cable connection disconnected
Detecting and Repairing Damage
Examples of damage are as follows
i Motor does not work
ii Motor function and overload relay trips
iii Motor function but only partially functional control circuit
Methods of detecting damage
Among the known methods necessary to detect damage are as follows
1 Turn off the electricity at the main switch (main switch) in order to avoid any danger during the
work carried out to detect damage
2 Check all the protective gear that controls the motor control main circuit
11 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
3 Make sure the damage function control circuit
4 Check the control circuit according to the schematic circuit diagram of the motor control
5 Check the operation of the control circuit
Note
Use wiring that has been installed on the SYSTEM OF MOTOR CONTROL BOARD by Forward
Reverse control circuit for Star Delta to test and look for damage
SELF-ASSESSMENT QUESTIONS
1 (a) Explain what is meant by the term lsquoback emfrsquo in a motor
(b) Outline the basic differences between series shunt and compound wound dc motors
2 (a) With the aid of diagrams explain how the speed of series shunt and compound-wound motors
may be controlled
(b) A 440V dc shunt-wound motor has a field resistance of 200R and an armature resistance of 06 R
When its speed is 20 rev d second the current drawn from the supply is 122A Calculate its back
emf at this speed If the speed were decreased to 19 revssecond the field flux remaining unchanged
calculate the new back emf and the new armature current
3 A load of 64 kW at 240 V is supplied from the terminals of a shunt-wound dc generator The field
resistance is 180 A Calculate the armature current
4 (a) Explain with the aid of a diagram how a rotating magnetic field may be
(b) What is meant by lsquosynchronous speedrsquo
Calculate the synchronous obtained speed of a 12 pole motor if the supply frequency is 50Hz
5 (a) Explain the action of a synchronous motor
(b) What methods are available to start a synchronous motor Explain with diagrams
6 (a) Explain the action of a cage induction motor
(b) What is meant by the term lsquosliprsquo
Calculate the percentage slip of a six pole induction motor running at 162 revssecond from a 50 Hz
supply
7 Describe with sketches three different ways of starting a single-phase induction motor
12 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
8 Explain with the aid of a sketch the action of a three-phase DOL starter
What are dashpots used for How are remote start and stop buttons connected
9 A I0 kW 240V 50Hz single-phase cage rotor induction motor is 85efficient and has a PF of 068
lagging Calculate the motor current and the value of capacitor required to raise the PF to 093
lagging
10 Calculate the torque developed by an 18 kW four-pole induction motor run at 35 slip from a
50Hz supply
APPENDIX 1
13 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 11
14 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 111
Attachment Reference
httpswwwtlc-directcoukBook621htm
httpwwwstgovmyindexphpms
15 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
iv Small metallic parts such as screws and name plates which are isolated by means of insulation
v Metallic lamp parts for filament lamps in water proof floors
57 Termination to Earth
The termination to earth is done as shown in Figure 72
Earth Electrode Resistance
The maximum permitted earth electrode resistance for different types of installations is as shown in
the Table below
Earth electrode for installations protected by RCDs of sensitivity 100mA 10 Ω
Lightning arrestor earth electrode 10 Ω
Legal Requirements
i Sub regulation 12(1) and 12(2) of the Electricity Regulations 1994 state that any electrical wiring in
an installation shall be under the immediate supervision of a Wireman with Single Phase Restriction or
Three Phase Restriction Upon completion the Wireman shall certify a Supervision and Completion
Certificate
ii Sub regulation 13(1) and 13 (2) of the Electricity Regulations 1994 state that the installation shall
be tested by a Wireman with Single Phase Restriction or a Wireman with Three Phase Restriction
authorized to test any installation and who shall certify a Test Certificate for the installation
iii Sub regulation 14(1) of the Electricity Regulations 1994 states that the Supervision and
Completion Certificate and the Test Certificate as in regulations 12 and 13 shall be in Forms G and H
respectively as prescribed in the First Schedule
17 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
4 SAFETY REQUIREMENTS FOR ELECTRICAL WIRING WORKS IN RESIDENTIAL BUILDINGS
61 Safety Requirements
Safety requirements for electrical wiring works have to be followed to eliminate any accidents which
can result in physical damage or loss of life or property Failure to meet the safety regulations may
result in workers consumers or the public being inflicted with electrical shocks
In addition to this safety steps will also encourage workers or electricity consumers who are
disciplined and who always give importance to safety
62 Safety Steps
Safety requirements have to be followed whenever electrical works are undertaken in a residential
building
i Personal Safety
a Use suitable personal protection equipment as needed such as safety shoes gloves safety helmet
etc when at the work place
b Use safety clothing suitable for the work to be undertaken
c Do not wear jewellery or decorative items such as rings watches chains etc while carrying out
electrical works
ii Safety at the Work Place
a Acquire knowledge about the dangers of electrical works that is to be undertaken and how to deal
with those dangers
b Always adhere to the safety regulations which have been set for the work place
c Ensure that the electricity supply is switched off before carrying out the works
d Acquire the needed knowledge and practice a cautious and calm attitude while working ensure
cleanliness in and around fellow workers
e While working at elevated places the worker should always use suitable equipment such as wooden
or aluminium ladders iron scaffoldings or platforms safety belts or other equipment needed to ensure
that the work can be undertaken safely
f Use electrical equipment which is operational and safe to be used and ensure that the supply for it is
being supplied through a residual current device (RCD) with a sensitivity of 30 mA
g Ensure that exposed temporary supply electrical cables have mechanical protection
h If inflammable or corrosive material is present necessary safety steps have to be undertaken as
required by the relevant safety regulations
63 Dangers of Electrical Shocks
i Electrical Shock
Electrical shocks can occur due to direct or indirect contact
a Direct Contact
18 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Direct contact occurs when the worker or consumer receives an electrical shock on touching directly a
live conductor or cable
b Indirect Contact
Here the electric shock occurs due to contact with a part which is connected to the electrical
installation and not to a direct contact with a live cable or conductor possibly due to damages in the
appliance or insulation resulting in leakages of current
Why Electric Shocks Occura Unsafe Work Method or Action Undertaking Electrical Work Without Disconnecting the
Supply
Maintenance or circuit testing work done without disconnecting the supply will have a high possibility
of electrical shocks occurring
bull Not Following Safe Work Procedures
To eliminate the occurrence of electrical shocks each worker has to always follow safe work
procedures which are set by regulations and standards
b Defects in the Electrical System
i Leakage Current
Leakage currents or earth leakage currents can result in the metallic frames becoming live and
energised This can give rise to the danger of electrical shock to the worker consumer or the public if
they hold or come into contact with the metallic frame
ii Exposed Conductor or Disconnected Cable
Exposed conductors or cables which are broken and are alive (energised) can result in electrical shock
when touched The supply source must be immediately isolated or switched off and a report must be
made to the responsible entity
64 First Aid and Basic Pulmonary Resuscitation
i First Aid
First aid is the initial assistance given to a person who has met with an accident is sick or is injured to
prevent the condition of the victim from becoming more serious while awaiting the arrival of the
paramedics (ambulance) or before being brought to the hospital
i Pulmonary Resuscitation
Pulmonary resuscitation has to be undertaken to assist the victim who has breathing difficulties as a
result of being drowned receiving an electrical shock etc Pulmonary resuscitation has to be carried
out in accordance to the correct method as stated in the first aid manuals issued by accredited first aid
bodies
ii First Aid Box
19 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
A first aid box has to be provided by the building owner construction site supervisor or brought
personally by the worker under the supervision of the responsible person
65 Training Programme
The management shall conduct periodic training programmes for the workers with regards to work
safety on aspects including the following -
i Dangers of electrical work being undertaken and how to control those dangers
ii The safety regulations set for the work place and
iii First aid procedures
66 Fire Prevention
Fire Extinguisher A suitable functioning fire extinguisher to control fires has to be made available at
the work place at all times
67 Competent Person
The Electricity Regulations 1994 require that all electrical work has to be undertaken by or under the
direct supervision of a competent person registered with the Energy Commission Besides that the
electrical contractor undertaking the electrical work has also to be registered with the Energy
Commission The installation owner thus has to ensure that the appointed electrical contractor is
registered with the Energy Commission and that the registration is still valid
INSTALLATION CIRCUITS AND SYSTEMS1 Block diagrams
These show using squares rectangles etc the sequence of a system without too much technical detail
eg Figures 1517 and 1526
2 Layout diagrams
These are very similar to block diagrams but they indicate more technical detail and tend to show
items in their correct geographical location (eg Figures 1518 and 1519)
3 Circuitschematic
These show how a circuit functions and takes no account of exact locations of terminals or equipment
(eg Figures 1528 1529 1532 1534 etc)
4 Wiring diagram
These indicate how a circuit or system is physically wired (eg Figures 152 154 156 etc)
Most induction motors are started directly on line but when very large motors are started that way
they cause a disturbance of voltage on the supply lines due to large starting current surges To limit the
starting current surge large induction motors are started at reduced voltage and then have full supply
voltage reconnected when they run up to near rotated speed Two methods are used for reduction of
starting voltage are star delta starting and auto transformer stating
20 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Working Principal of Star-Delta Starter
This is the reduced voltage starting method Voltage reduction during star-delta starting is achieved by
physically reconfiguring the motor windings as illustrated in the figure below During starting the
motor windings are connected in star configuration and this reduces the voltage across each winding 3
This also reduces the torque by a factor of three After a period of time the winding are reconfigured as
delta and the motor runs normally
StarDelta starters are probably the most common reduced voltage starters They are used in
an attempt to reduce the start current applied to the motor during start as a means of reducing the
disturbances and interference on the electrical supply
Traditionally in many supply regions there has been a requirement to fit a reduced voltage
starter on all motors greater than 5HP (4KW) The StarDelta (or WyeDelta) starter is one of the
lowest cost electromechanical reduced voltage starters that can be applied
The StarDelta starter is manufactured from three contactors a timer and a thermal overload
The contactors are smaller than the single contactor used in a Direct on Line starter as they are
controlling winding currents only The currents through the winding are 1root 3 (58) of the
current in the line
There are two contactors that are close during run often referred to as the main contractor and
the delta contactor These are AC3 rated at 58 of the current rating of the motor The third
contactor is the star contactor and that only carries star current while the motor is connected in star
The current in star is one third of the current in delta so this contactor can be AC3 rated at one
third (33) of the motor rating
Star-delta Starter Consists following units
1) Contactors (Main star and delta contactors) 3 Norsquos (For Open State Starter) or 4 Norsquos (Close
Transient Starter)
2) Time relay (pull-in delayed) 1 No
3) Three-pole thermal over current release 1No
4) Fuse elements or automatic cut-outs for the main circuit 3 Nos
5) Fuse element or automatic cut-out for the control circuit 1No
Power Circuit of Star Delta Starter
1 The main circuit breaker serves as the main power supply switch that supplies electricity to the
power circuit
2 The main contactor connects the reference source voltage R Y B to the primary terminal of the
motor U1 V1 W1
21 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
3 In operation the Main Contactor (KM3) and the Star Contactor (KM1) are closed initially and
then after a period of time the star contactor is opened and then the delta contactor (KM2) is
closed The control of the contactors is by the timer (K1T) built into the starter The Star and Delta
are electrically interlocked and preferably mechanically interlocked as well In effect there are
four states
4 The star contactor serves to initially short the secondary terminal of the motor U2 V2 W2 for the
start sequence during the initial run of the motor from standstill This provides one third of DOL
current to the motor thus reducing the high inrush current inherent with large capacity motors at
startup
5 Controlling the interchanging star connection and delta connection of an AC induction motor is
achieved by means of a star delta or wye delta control circuit The control circuit consists of push
button switches auxiliary contacts and a timer
Control Circuit of Star-Delta Starter (Open Transition)
1 The ON push button starts the circuit by initially energizing Star Contactor Coil (KM1) of star
circuit and Timer Coil (KT) circuit
2 When Star Contactor Coil (KM1) energized Star Main and Auxiliary contactor change its
position from NO to NC
3 When Star Auxiliary Contactor (1)( which is placed on Main Contactor coil circuit )became
NO to NC itrsquos complete The Circuit of Main contactor Coil (KM3) so Main Contactor Coil
energized and Main Contactorrsquos Main and Auxiliary Contactor Change its Position from NO
To NC This sequence happens in a friction of time
4 After pushing the ON push button switch the auxiliary contact of the main contactor coil (2)
which is connected in parallel across the ON push button will become NO to NC thereby
providing a latch to hold the main contactor coil activated which eventually maintains the
control circuit active even after releasing the ON push button switch
5 When Star Main Contactor (KM1) close its connect Motor connects on STAR and itrsquos
connected in STAR until Time Delay Auxiliary contact KT (3) become NC to NO
6 Once the time delay is reached its specified Time the timerrsquos auxiliary contacts (KT)(3) in
Star Coil circuit will change its position from NC to NO and at the Same Time Auxiliary
contactor (KT) in Delta Coil Circuit(4) change its Position from NO To NC so Delta coil
energized and Delta Main Contactor becomes NO To NC Now Motor terminal connection
change from star to delta connection
7 A normally close auxiliary contact from both star and delta contactors (5amp6)are also placed
opposite of both star and delta contactor coils these interlock contacts serves as safety
switches to prevent simultaneous activation of both star and delta contactor coils so that one
22 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
cannot be activated without the other deactivated first Thus the delta contactor coil cannot be
active when the star contactor coil is active and similarly the star contactor coil cannot also
be active while the delta contactor coil is active
8 The control circuit above also provides two interrupting contacts to shutdown the motor
The OFF push button switch break the control circuit and the motor when necessary The
thermal overload contact is a protective device which automatically opens the STOP Control
circuit in case when motor overload current is detected by the thermal overload relay this is to
prevent burning of the motor in case of excessive load beyond the rated capacity of the motor
is detected by the thermal overload relay
9 At some point during starting it is necessary to change from a star connected winding to a
delta connected winding Power and control circuits can be arranged to this in one of two
ways ndash open transition or closed transition
What is Open or Closed Transition Starting
(1) Open Transition Starters
Discuss mention above is called open transition switching because there is an open state between
the star state and the delta state
In open transition the power is disconnected from the motor while the winding are reconfigured via
external switching
When a motor is driven by the supply either at full speed or at part speed there is a rotating
magnetic field in the stator This field is rotating at line frequency The flux from the stator field
induces a current in the rotor and this in turn results in a rotor magnetic field
When the motor is disconnected from the supply (open transition) there is a spinning rotor within
the stator and the rotor has a magnetic field Due to the low impedance of the rotor circuit the time
constant is quite long and the action of the spinning rotor field within the stator is that of a
generator which generates voltage at a frequency determined by the speed of the rotor When the
motor is reconnected to the supply it is reclosing onto an unsynchronized generator and this result
in a very high current and torque transient The magnitude of the transient is dependent on the
phase relationship between the generated voltage and the line voltage at the point of closure can
be much higher than DOL current and torque and can result in electrical and mechanical damage
Open transition starting is the easiest to implement in terms or cost and circuitry and if the timing
of the changeover is good this method can work well In practice though it is difficult to set the
necessary timing to operate correctly and disconnectionreconnection of the supply can cause
significant voltagecurrent transients
In Open transition there are Four states
23 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 OFF State All Contactors are open
2 Star State The Main [KM3] and the Star [KM1] contactors are closed and the delta [KM2]
contactor is open The motor is connected in star and will produce one third of DOL torque at one
third of DOL current
3 Open State This type of operation is called open transition switching because there is an
open state between the star state and the delta state The Main contractor is closed and the Delta
and Star contactors are open There is voltage on one end of the motor windings but the other end
is open so no current can flow The motor has a spinning rotor and behaves like a generator
4 Delta State The Main and the Delta contactors are closed The Star contactor is open The
motor is connected to full line voltage and full power and torque are available
(2) Closed Transition StarDelta Starter
There is a technique to reduce the magnitude of the switching transients This requires the use of a
fourth contactor and a set of three resistors The resistors must be sized such that considerable
current is able to flow in the motor windings while they are in circuit
The auxiliary contactor and resistors are connected across the delta contactor In operation just
before the star contactor opens the auxiliary contactor closes resulting in current flow via the
resistors into the star connection Once the star contactor opens current is able to flow round
through the motor windings to the supply via the resistors These resistors are then shorted by the
delta contactor If the resistance of the resistors is too high they will not swamp the voltage
generated by the motor and will serve no purpose
In closed transition the power is maintained to the motor at all time This is achieved by
introducing resistors to take up the current flow during the winding changeover A fourth
contractor is required to place the resistor in circuit before opening the star contactor and then
removing the resistors once the delta contactor is closed These resistors need to be sized to carry
the motor current In addition to requiring more switching devices the control circuit is more
complicated due to the need to carry out resistor switching
In Close transition there are Four states
1 OFF State All Contactors are open
2 Star State The Main [KM3] and the Star [KM1] contactors are closed and the delta [KM2]
contactor is open The motor is connected in star and will produce one third of DOL torque at one
third of DOL current
Star Transition State The motor is connected in star and the resistors are connected across the
delta contactor via the aux [KM4] contactor
24 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Closed Transition State The Main [KM3] contactor is closed and the Delta [KM2] and Star
[KM1] contactors are open Current flows through the motor windings and the transition resistors
via KM4
Delta State The Main and the Delta contactors are closed The transition resistors are shorted out
The Star contactor is open The motor is connected to full line voltage and full power and torque
are available
Effect of Transient in Starter (Open Transient starter)
It is Important the pause between star contactor switch off and Delta contactor switch is on correct
This is because Star contactor must be reliably disconnected before Delta contactor is activated It
is also important that the switch over pause is not too long
For 415v Star Connection voltage is effectively reduced to 58 or 240v The equivalent of 33
that is obtained with Direct Online (DOL) starting
If Star connection has sufficient torque to run up to 75 or 80 of full load speed then the motor
can be connected in Delta mode
When connected to Delta configuration the phase voltage increases by a ratio of V3 or 173 The
phase currents increase by the same ratio The line current increases three times its value in star
connection
During transition period of switchover the motor must be free running with little deceleration
While this is happening ldquoCoastingrdquo it may generate a voltage of its own and on connection to the
supply this voltage can randomly add to or subtract from the applied line voltage This is known as
transient current Only lasting a few milliseconds it causes voltage surges and spikes Known as
a changeover transient
Size of each part of Star-Delta starter
(1) Size of Over Load Relay
For a star-delta starter there is a possibility to place the overload protection in two positions in the
line or in the windings
Overload Relay in Line
In the line is the same as just putting the overload before the motor as with a DOL starter
The rating of Overload (In Line) = FLC of Motor
Disadvantage If the overload is set to FLC then it is not protecting the motor while it is in delta
(setting is x1732 too high)
Overload Relay in Winding
25 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
In the windings means that the overload is placed after the point where the wiring to the contactors
are split into main and delta The overload then always measures the current inside the windings
The setting of Overload Relay (In Winding) =058 X FLC (line current)
Disadvantage We must use separate short circuit and overload protections
(2) Size of Main and Delta Contractor
1 There are two contactors that are close during run often referred to as the main contractor and
the delta contactor These are AC3 rated at 58 of the current rating of the motor
Size of Main Contactor= IFL x 058
(3) Size of Star Contractor
The third contactor is the star contactor and that only carries star current while the motor is
connected in star The current in star is 1 radic3= (58) of the current in delta so this contactor can
be AC3 rated at one third (33) of the motor rating
Size of Star Contactor= IFL x 033
Motor Starting Characteristics of Star-Delta Starter
Available starting current 33 Full Load Current
Peak starting current 13 to 26 Full Load Current
Peak starting torque 33 Full Load Torque
Advantages of Star-Delta starter
The operation of the star-delta method is simple and rugged
It is relatively cheap compared to other reduced voltage methods
Good TorqueCurrent Performance
It draws 2 times starting current of the full load ampere of the motor connected
Disadvantages of Star-Delta starter
Low Starting Torque (Torque = (Square of Voltage) is also reduce)
Break In Supply ndash Possible Transients
Six Terminal Motor Required (Delta Connected)
It requires 2 set of cables from starter to motor
It provides only 33 starting torque and if the load connected to the subject motor requires higher
starting torque at the time of starting than very heavy transients and stresses are produced while
changing from star to delta connections and because of these transients and stresses many
electrical and mechanical break-down occurs
26 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
In this method of starting initially motor is connected in star and then after change over the motor
is connected in delta The delta of motor is formed in starter and not on motor terminals
High transmission and current peaks When starting up pumps and fans for example the load
torque is low at the beginning of the start and increases with the square of the speed When
reaching approx 80-85 of the motor rated speed the load torque is equal to the motor torque and
the acceleration ceases To reach the rated speed a switch over to delta position is necessary and
this will very often result in high transmission and current peaks In some cases the current peak
can reach a value that is even bigger than for a DOL start
Applications with a load torque higher than 50 of the motor rated torque will not be able to start
using the start-delta starter
Low Starting Torque The star-delta (wye-delta) starting method controls whether the lead
connections from the motor are configured in a star or delta electrical connection The initial
connection should be in the star pattern that results in a reduction of the line voltage by a factor of
1radic3 (577) to the motor and the current is reduced to 13 of the current at full voltage but the
starting torque is also reduced 13 to 15 of the DOL starting torque
The transition from star to delta transition usually occurs once nominal speed is reached but is
sometimes performed as low as 50 of nominal speed which make transient Sparks
Features of star-delta starting
1 For low- to high-power three-phase motors
2 Reduced starting current
3 Six connection cables
4 Reduced starting torque
5 Current peak on changeover from star to delta
6 Mechanical load on changeover from star to delta
Application of Star-Delta Starter
The star-delta method is usually only applied to low to medium voltage and light starting
Torque motors
The received starting current is about 30 of the starting current during direct on line start and the
starting torque is reduced to about 25 of the torque available at a DOL start This starting
method only works when the application is light loaded during the start If the motor is too heavily
27 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
loaded there will not be enough torque to accelerate the motor up to speed before switching over
to the delta position
LESSON 1 WIRING SYSTEM OF SINGLE PHASE DISTRIBUTION BOARD
Introduction
28 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
29 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
30 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
31 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 2 WIRING SYSTEM OF SINGLE PHASE LIGHTING CIRCUIT Introduction
Objectives
1 Identify component and the specification
2 Wire component according to the schematic diagram
3 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Wiring bay Perforated metal 180 cm x 180 cm 1
2 Cut out fuse 63 A 240 V 1
3 Neutral link 1
4 Single pole one way switch cw
switch box
5A 240Vac 4
5 single pole two way switch cw
switch box
5A 240Vac 2
6 RCCB In = 40 A Tripping current
100mA240 Vac 50 Hz
1
7 Main switch 32 A 240V 1
8 kWatthour meter 40 A 240 Vac 1
9 Single pole MCB 6A 240 Vac 1
10 Self tapping Wood screw As required
11 DIN rail 35 mm width As required
32 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
12 PVC trunking 50 mm x 50 mm As required
13 Terminal blocks 5 A As required
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
1 One way switch to control one lamp
2 One way switch to control two lamps
3 Two of two way switch to control one lamp
4 Two of single pole two way switch and one of an intermediate switch to control one
lamp
5 One unit of ceiling fan and fan regulator to be controlled by one way switch
4 Test the functionality of completed project
LESSON 3ndash WIRING SYSTEM OF SINGLE PHASE POWER CIRCUIT Introduction
33 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
34 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify types of component and its specification
2 Wire component according to the schematic diagram given
3 Test the functionality of the circuit dead circuit test life circuit test
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board Perforated Metal 1
2 kWh meter 240 V 40 A 1
3 Socket outlet 13A 240Vac 4
4 RCCB 40A Trip Amps
30mA240 Vac
1
5 3 pin socket 240Vac 13A 4
6 Single pole MCB 20A 240 V 2
7 DOL starter 1 kW 240Vac 2
8 1 phase induction motor 2Hp 240 Vac 1
9 Cooker control unit 4kW 240Vac 1
10 Water heater point 4kW 240 Vac 1
11 DIN rail 35 mm As required
12 PVC casing 20mm As required
13 Flexible wires 05 mm As required
14 Terminal block 10 A As required
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Wire two unit of 13 A socket outlet in radial circuit
3 Wire four units of 13 A socket outlet in ring circuit
4 Wire one unit DOL starter for air-conditioner point
5 Wire one unit of cooker control unit point
6 Wire one unit of water heater point
7 Test the functionality of each component by using mmeter or power supply whichever
applicable
8 Wire component according to circuit diagram
9 Test the functionality of completed project dead circuit test life circuit test
Note
35 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Ensure that the correct rating of protection device and size of wire used
LESSON 4ndash CONDUIT BENDING AND TRUNKING FABRICATION TECHNIQUE
Common fitting used in an industrial wiring
Cutting and threading the condute
36 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
37 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
38 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify conduit fitting and the specification
2 Measure and Cut steel conduit according to specified dimension
3 Bend and fabricate conduit at 45 90 according to layout diagram
4 Wire component according to the schematic diagram
5 Test the functionality of the circuit
39 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Conduit Bender Oslash 19 mm ( frac34 ldquo) 1
2 Measuring Tape 3 metre 1
3 Hacksaw frame and blade 30cm 1
4 Conduit cutter 1
5 Pipe Vise 1
6 Pipe Wrench 1
7 Ratchet Dies 20 mm 1
8 Metal trunking 50 mm x 50 mm 1
9 GI conduit 20mm 1
10 End box 20 mm 1
11 Flexible wires 05 mm As required
12 Connectors 5 A As required
13 Single core PVC ins Cable 25 mm 2 As required
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Wire two unit of 13 A socket outlet in radial circuit
3 Wire four unit of 13 A socket outlet in ring circuit
4 Wire one unit DOL starter for air-conditioner point
5 Wire one unit of cooker control unit point
6 Wire one unit of water heater point
7 Test the functionality of each component by using multimeter or power supply whichever
applicable
8 Wire component according to circuit diagram
9 Test the functionality of completed project
Note
Ensure that the rating of protection device and size of wire
K prior to 31 March
2004 (BS 7671)
(formerly)
bare conductor
sleeved at terminations (formerly)
40 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 5 ndashWIRING SYSTEM OF 1 Oslash LIGHTING AND POWER CIRCUIT
POWER CIRCUITSa Radial circuits
Radial circuits are arranged in the same way as item 1 above in lighting layouts in that each socket
outlet is supplied via the previous one
Points to note
1 The number of socket outlets complying with BS 1363 is unlimited for a floor area of up to 50m 2 if
the circuit protection is a 30 A or 32 A cartridge fuse or circuit breaker the cable being 4 mm PVC
copper or 25 mm2 mineral insulated (mi)
2 The number of socket outlets is unlimited for a floor area up to 20 m 2 with any type of circuit
protection of 20 A using 25 mm2 PVC copper cable or 15 mm2 mi
3 The total number of fused spurs is unlimited
b ring final circuits
These circuits are the same as radial circuits except that the final socket outlet is wired back to the
supply position In effect any outlet is supplied from two directions (Fig 152)
Points to note
1 Every twin-socket outlet counts as two single-socket outlets
2 The number of non-fused spurs must not exceed the total number of points on the ring Fig 158
shows seven points on the ring and five spurs
3 The fuse rating of a fused spur box must not exceed 13 A and the current rating of all points supplied
by the fused spur must not exceed 13 A
4 Non-fused spurs must supply no more than one single or one double socket on the ring Fig 158
shows seven points on the ring and five spurs rating of all points supplied by the fused spur must not
exceed 13 A or one stationary appliance
CapacityMain conductor size
copper (mm2)
Earth conductor
size (mm2)
Circuit breaker
capacity (A)
Up to 600 W 15 15 6
600ndash1200 W 1525 15 10
1200ndash1800 W 254 25 16
41 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Ring circuit
(floor area 100 m2)25 15 3032
A2 radial circuit
(floor area 75 m2)40 25 3032
A3 radial circuit
(floor area 50 m2)25 15 20
Air conditioner (15 tonne) 60 60 3032
Cooker 60 60 3032
Water heater 40 40 20
Objectives
1 Identify component and the specification
2 Wire component according to the schematic diagram
3 Test the functionality of the circuit
42 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board Perforated 1
2 Cut out fuse and neutral link 60A 240V 1each
3 kWh meter 240V 40A 1
4 Switched Socket outlet 13A 240Vac 4
5 Single pole two way switch cw switch
box
5A 240Vac 2
6 RCCB ELCB 63 A Tripping current 100mA
415 Vac
1
7 3 pin plug 240Vac 13A 4
8 Single pole MCB 20 A 2
9 Single pole MCB 6A 1
10 Single pole MCB 20A 2
11 DOL starter 240Vac 2
12 1 phase induction motor 2hp 240 Vac 1
13 Self tapping Wood screw As required
14 DIN rail Stainless steel allum35 mm As required
15 PVC pipe 20mm dia As required
16 End box 20 mm dia 4
17 Flexible wires 05 mm 2 As required
18 Connectors 5 A As required
Procedures
43 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
4 Test the functionality of completed project
LESSON 6 ndash WIRING SYSTEM OF 3 Oslash DISTRIBUTION BOARD
Introduction
44 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
45 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
46 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
47 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
48 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify each component and the specification
2 Wire component according to the schematic diagram given
3 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting Board 450 x 600 mm Perforated metal 1
2 5 pin round socket and plug 415V ac 32A 1
3 Cut out fuse 60 A 3
4 Neutral link 1
5 kWatt hour meter 415V 60A 1
6 ELCB RCCB 3P+N In=63A415 Vac I trip= 300mA 1
7 ELCB RCCB 3P+N In=63A415 Vac I trip= 30mA 1
8 Single pole MCB 6A 240 V 3
9 Single pole MCB 20A 240 V 3
10 DOL starter 20 A 240Vac 2
11 Socket outlet 15 A 240 Vac 1
12 Switched Socket outlet 13 A 240 Vac 3
13 Led indicating light 5A 240 Vac 3
14 Single pole 4 gang 1 way switch 5A 240 Vac 2
15 Single pole 2 way switch 5A 240 Vac 2
16 1 phase induction motor 1 kW 240Vac 1
17 Metal trunking 30 mm x30 mm As required
18 Self tapping Wood screw 4 mm x 20 mm As required
19 DIN rail 25 mm x 1mm
20 GI steel rigid conduit 20mm As required
21 Flexible conduit 20mm As required
22 End box 20 mm 4
23 Flexible wires 05 mm 2 As required
24 Single core PVC insulated wire 15 mm 2 As required
25 Single core PVC insulated wires 25 mm 2 As required
26 Terminal block 10 A As required
Procedures
49 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify each components and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
4 Test the functionality of completed project
1 dead circuit test
2 life circuit
Note Proper earthing should be made
50 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 7 ndash WIRING SYSTEM OF THREE PHASE LIGHTING AND POWER CIRCUIT
51 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
52 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify component and the specification
2 Wire component according to the schematic diagram
3 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting bay Board Perforated metal 180 cm x 180 cm 1
2 k Watt hour meter 415V 60A 1
3 MCCB 415V 60A
4 ELCB RCCB In=60A415 Vac I trip=30mA 1
5 5 pin round Socket and
plug
415Vac 32A 4
6 Single pole MCB 6A 1
7 Triple pole MCB 20A 2
8 Triple pole Main switch 60A 1
9 DOL starter 240Vac 2
10 3 phase induction motor 2hp 415 Vac 1
11 1 phase induction motor 1
12 Metal trunking 30 mm x30 mm As required
13 Self tapping Wood screw 4 mm x 20 mm As required
14 DIN rail 25 mm x 1mm
15 GI steel rigid conduit 20mm As required
16 Flexible conduit 20mm As required
17 End box 20 mm 4
18 Flexible wires 05 mm As required
19 Connectors 10 A As required
Procedures
1 Identify each components and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
4 Test the functionality of completed project
1 dead circuit 2 life circuit test
5 Record the current drawn by the load as connected in star and delta
Note Proper earthing should be made
53 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 8 INSPECTION AND TESTING OF ELECTRICAL INSTALLATION
On completion of a wiring installation a number of tests on the installation have to be conducted to
ascertain that the wiring circuits and connected appliances are safe for use Prior to carrying out the
tests an inspection has to be done The results of the inspectionsupervision and test have to be
presented in Form G (as in Appendix IV) and Form H (as in Appendix V)
To have the test certification as in Form H the following tests shall be conducted
i Continuity Test
ii Insulation Resistance Test
iii Polarity Test
iv Earth Electrode Resistance test and
v Residual Current Device Test
1 Continuity Test
There are 3 main types of continuity tests for the final circuits-
i Protection Conductor Continuity Test
ii Final Ring Circuit Conductor Continuity Test
iii Live and Neutral Conductor Continuity Test
a) Protection Conductor Continuity Test
bull To ascertain that all protection conductors are connected in the correct and effective manner
bull Test equipment ndash Multimeter (Ohm range) or Ohm meter
54 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
bull Test Method
1 1048766 Ensure that the main switch RCD and MCB are open circuited (switched off) and all loads
are disconnected
2 1048766 Connected the test leads as in the Figure 81 The meter reading shall be less than 1 Ω
55 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Final Ring Circuit Conductor Continuity Test
bull To ensure that all conductors around the ring circuit have continuity
bull Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
bull Test Method
1 1048766 Disconnect both the supply source live conductors from the MCB the neutral conductor
from the neutral terminals and the earth conductor from the earth terminal in the distribution
fuse box
2 1048766 Connect the test leads as in the Figure 82 (EE)
3 1048766 Repeat the procedure for (L-L) and (N-N)
4 1048766 The meter reading value shall be less than 1 ohm
56 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Live and Neutral Conductor Continuity Test
a To ensure that each conductor in the circuit has continuity
b Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
2 Test Method
1 1048766 Switch off the Main switch RCD and MCB
2 1048766 Disconnect all loads
3 1048766 Switch on all switches in the circuit
4 1048766 Disconnect the fusesfinal circuit breakers and close the circuit
5 1048766 Carry out the test as shown in Figure 83
6 1048766 The meter reading value shall be less than 1Ω
57 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
58 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
CONTINUITY TEST
Insulation Resistance Test
i Ensure that there is no leakage current between phase conductors phase and neutral conductors and
phase conductor and earth
ii Test the strength of the cable insulation
iii Test Equipment ndash Insulation Resistance Tester operating voltage is 250VDC or 500VDC
iv Test Method
1 1048766 Switch off main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
59 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
4 1048766 Carry out test as in the Table below
5 1048766 Meter reading value shall be less than 1 Megaohm
60 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
61 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Insulation resitance test
62 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
INSULATION RESISTANCE TEST BETWEEN CONDUCTORS AND OPPOSITE POLARITY
Polarity Testi Ensure that each fuse or single pole control and protection device is connected only in the phase
conductor
ii Intermediate contact of Edison screw lamp holder is connected to the phase conductor
iii Ensure that phase neutral and earth conductors at socket outlets are connected at the correct
terminals
iv Test Equipment ndash Multimeter (Ohm range) or Ohm meter
v Test Method
1 1048766 Switch off Main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in Figure 85
63 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
5 1048766 Test switches and single phase control devices at the phase conductors
6 1048766 Test socket outlet connection sources
7 1048766 Test Edison screw lamp holder connections
8 1048766 Meter reading value shall be less than 1 Ω
64 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Polarity test
65 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Earth Electrode Resistance Testi To test the earth electrode resistance
ii To ascertain the suitability of the location of the electrode
iii To ensure that the electrode is not buried within the resistance area of another electrode
iv Test equipment ndash Earth Resistance Tester
v Test method -
1 1048766 Terminal rsquoErsquo is connected to the electrode to be tested (green conductor)
2 1048766 Terminal lsquoPrsquo is connected to the potential spike (yellow conductor) at a distance of 10
meters from the earth electrode
3 1048766 Terminal lsquoCrsquo is connected to the current spike (red conductor) at a distance of 20 meters
from the earth electrode
Earth Electrode Resistance Measurement Method (Figure 86)
This test must be repeated at least three times to ensure that the reading is not affected by interacting
earthing regions
i Record the first reading (Z1) Example Z1 = 10 Ω
ii Move the voltage spike to a distance of 6 meters from the original position Record the second
reading (Z2 ) Example Z2 = 10 Ω
iii Move the voltage spike to a distance of 6 meters from the original position Record the third
reading (Z3) Example Z3 = 10 Ω
66 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Residual Current Device Testi Ensure that the residual current device (RCD) trips within the set time on the occurrence of current
leakage to earth
ii Test Equipment ndash RCD Tester RCCB Tester
iii Test Method 1
1 1048766 Use the Trip Test Button
2 1048766 Press the trip button found on the RCD to determine if it trips or otherwise This test would
not be able to determine the sensitivity of the RCD nor the time taken for it to trip
iv Test Method 2
i 1048766 Use a RCD Tester
ii This equipment is equipped with a 13A plug which can be connected to a 13A socket outlet
Select the RCD sensitivity to be the same as the sensitivity of the RCD to be tested to
determine if the RCD can trip The time to trip shall not exceed 40 mS
iii 1048766 Test method ndash
a) Position the selection switch in accordance with the sensitivity of the RCD used
Example 100 mA 01 A
b) Position the operations switch to lsquoNo Triprsquo (frac12 Rated mA = 50) connect the 3 pin plug to
the 13A socket outlet
67 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
c) Switch on the 13A socket outlet ndash ensure that the P-N and P-E lights light up
This shows that the polarity is correct (Note if both the lights as above do not light up the test cannot
be continued)
d) Press the test button ndash the reading shows less than 200 mS and simultaneously the lsquotestrsquo light lights
up and the P-N and P-E lights do not light up At that instant the RCD will not trip
e) Move the selection switch to 180o (+ve wave) ndash repeat steps (d) and (e) Move the operations
switch to lsquoTriprsquo (Rated mA = 100)
g) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200mS
h) Move the selection switch to 0o (-ve wave)
i) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
j) The above test is repeated until a near correct reading is obtained
k) Record the test results
l) Change the operations switch to lsquoFast Triprsquo and press the test button ndash RCD will trip within a
time not exceeding 40 millisecond
m) Repeat a number of times at 0o or 180o
On completion of a wiring installation a number of tests on the installation have to be conducted to
ascertain that the wiring circuits and connected appliances are safe for use Prior to carrying out the
tests an inspection has to be done the following tests shall be conducted
i Continuity Test
ii Insulation Resistance Test
iii Polarity Test
iv Earth Electrode Resistance test and
v Residual Current Device Test
821 Continuity Test
There are 3 main types of continuity tests for the final circuits-
i Protection Conductor Continuity Test
ii Final Ring Circuit Conductor Continuity Test
68 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
iii Live and Neutral Conductor Continuity Test
a) Protection Conductor Continuity Test
bull To ascertain that all protection conductors are connected in the correct and effective manner
bull Test equipment ndash Multimeter (Ohm range) or Ohm meter
bull Test Method
1 1048766 Ensure that the main switch RCD and MCB are open circuited (switched off) and all loads are
disconnected
2 1048766 Connected the test leads as in the Figure 81
3 1048766 The meter reading shall be less than 1 Ω
Final Ring Circuit Conductor Continuity Test
bull To ensure that all conductors around the ring circuit have continuity
bull Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
bull Test Method
1 1048766 Disconnect both the supply source live conductors from the MCB the neutral conductor
from the neutral terminals and the earth conductor from the earth terminal in the distribution
fuse box
2 1048766 Connect the test leads as in the Figure 82 (EE)
3 1048766 Repeat the procedure for (L-L) and (N-N)
4 1048766 The meter reading value shall be less than 1 ohm Figure 82 - Final Ring Circuit Conductor
Continuity Test Ohm Meter
Disconnect both the supply source cables from mcbfuse
Take readings at earth conductors of both sources and note resistance readings
Live and Neutral Conductor Continuity Test
1 To ensure that each conductor in the circuit has continuity
2 Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
3 Test Method
1 1048766 Switch off the Main switch RCD and MCB
2 1048766 Disconnect all loads
3 1048766 Switch on all switches in the circuit
4 1048766 Disconnect the fusesfinal circuit breakers and close the circuit
5 1048766 Carry out the test as shown in Figure 83
6 1048766 The meter reading value shall be less than 1 ohm Figure 83 - Live and Neutral
Conductor Continuity Test Ohm Meter
Insulation Resistance Test
69 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
i Ensure that there is no leakage current between phase conductors phase and neutral conductors and
phase conductor and earth
ii Test the strength of the cable insulation
iii Test Equipment ndash Insulation Resistance Tester Operating voltage is 250VDC or 500VDC
iv Test Method
1 1048766 Switch off main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in the Table below
5 1048766 Meter reading value shall be less than 1 Megaohm
Polarity Test
i Ensure that each fuse or single pole control and protection device is connected only in the phase
conductor
ii Intermediate contact of Edison screw lamp holder is connected to the phase conductor
iii Ensure that phase neutral and earth conductors at socket outlets are connected at the correct
terminals
iv Test Equipment ndash Multimeter (Ohm range) or Ohm meter
v Test Method
1 1048766 Switch off Main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in Figure 85
5 1048766 Test switches and single phase control devices at the phase conductors
6 1048766 Test socket outlet connection sources
7 1048766 Test Edison screw lamp holder connections
8 1048766 Meter reading value shall be less than 1 Ω
Earth Electrode Resistance Test
i To test the earth electrode resistance
70 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
ii To ascertain the suitability of the location of the electrode
iii To ensure that the electrode is not buried within the resistance area of another electrode
iv Test equipment ndash Earth Resistance Tester
v Test method -
1 1048766 Terminal rsquoErsquo is connected to the electrode to be tested (green conductor)
2 1048766 Terminal lsquoPrsquo is connected to the potential spike (yellow conductor) at a distance of 10
meters from the earth electrode
3 1048766 Terminal lsquoCrsquo is connected to the current spike (red conductor) at a distance of 20 meters
from the earth electrode E P C Electrode 10 meter 10 meter
Figure 86 ndash Earth Electrode Resistance Measurement Test Equipment
Earth Electrode Resistance Measurement Method (Figure 86)
This test must be repeated at least three times to ensure that the reading is not affected by interacting
earthing regions
i Record the first reading (Z1) Example Z1 = 10 Ω
ii Move the voltage spike to a distance of 6 meters from the original position Record the second
reading (Z2) Example Z2 = 10 Ω
iii Move the voltage spike to a distance of 6 meters from the original position Record the third
reading (Z3)
Example Z3 = 10 Ω
Residual Current Device Test
71 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
i Ensure that the residual current device (RCD) trips within the set time on the occurrence of current
leakage to earth
ii Test Equipment ndash RCD Tester RCCB Tester
iii Test Method 1
1 1048766 Use the Trip Test Button
2 1048766 Press the trip button found on the RCD to determine if it trips or otherwise This test would
not be able to determine the sensitivity of the RCD nor the time taken for it to trip
iv Test Method 2
1048766 Use a RCD Tester
This equipment is equipped with a 13A plug which can be connected to a 13A socket outlet Select the
RCD sensitivity to be the same as the sensitivity of the RCD to be tested to determine if the RCD can
trip The time to trip shall not exceed 40 mS
1048766 Test method ndash
a) Position the selection switch in accordance with the sensitivity of the RCD used
Example 100 mA 01 A
b) Position the operations switch to lsquoNo Triprsquo (frac12 Rated mA = 50) connect the 3 pin plug to
the 13A socket outlet
c) Switch on the 13A socket outlet ndash ensure that the P-N and P-E lights light up This shows that
the polarity is correct (Note if both the lights as above do not light up the test cannot be
continued)
d) Press the test button ndash the reading shows less than 200 millisecond and simultaneously the
lsquotestrsquo light lights up and the P-N and P-E lights do not light up At that instant the RCD will
not trip
e) Move the selection switch to 180o (+ve wave) ndash repeat steps (d) and (e) = 100)
f) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
g) Move the selection switch to 0o (-ve wave)
h) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
i) The above test is repeated until a near correct reading is obtained
j) Record the test results
k) Change the operations switch to lsquoFast Triprsquo and press the test button ndash RCD will trip within a
time not exceeding 40 mS
l) Repeat a number of times at 0o or 180o
72 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 9 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (DC)
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
73 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Start stop button 240Vac 5A 2
9 Filament lamp (Bulb ) 240Vac 40W 3
10 Overload Relay 415V 20A 3
11 Three phase induction motor 5 hp 3
12 Single phase step down transformer 2500VA 1
13 Single core PVC insulated Cable 1mm 2 As required
14 Single core PVC insulated Cable 25mm 2 As required
15 DIN rail 35 mm As required
16 PVC type Cable tray 50 mm x 50 mm As required
17 Cable ties 4 ldquo As required
18 Flexible wires 05 mm As required
19 PVC Connectors 5 A amp 20 A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the schematic
diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a optional exercise
i Simple DOL starter
ii Forward reverse DOL starter
iii Forward Reverse Dahlander motor
iv Three motors operated in sequence by DOL starter operated by manual push
button or time delay relay
74 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
a One loop per-cycle
b Continuous operation in a loop
c optional circuit design to represent the same task
v Only one out of three motors to be operated at a time (quiz)
4 Test the functionality of completed project
LESSON 10 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (AC)
75 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 1
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Lamp point 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
76 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
11 Overload Relay 415V 20A 3
12 Three phase induction
motor
5 hp 3
13 Single core PVC insulated
Cable
1mm 2 As required
14 Single core PVC insulated
Cable
25mm 2 As required
15 DIN rail 35 mm As required
16 PVC type Cable tray 50 mm x 50 mm As required
17 Cable ties 4 ldquo As required
18 Flexible wires 05 mm As required
19 PVC Connectors 5 A amp 20 A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the
schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram optional exercise
4 Simple DOL starter
5 Forward reverse DOL starter
6 Test the functionality of completed project
77 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 1
78 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
cm
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Indicating light 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
11 Overload Relay 415V 20A 3
12 Three phase induction motor 5 hp 3
13 Single phase step down
transformer
2500VA 1
14 Single core PVC insulated
Cable
1mm 2 As required
15 Single core PVC insulated
Cable
25mm 2 As required
16 DIN rail 35 mm As required
17 PVC type Cable tray 50 mm x 50 mm As required
18 Cable ties 4 ldquo As required
19 Flexible wires 05 mm As required
20 PVC Connectors 5 A amp 20 A 240 V As required
21 Single pole MCB 6A 240 V 1
22 Single pole MCB 2A 240 V 1
23 Triple pole MCB 20A 415 V 1
24 Mounting board 30 cm x 40 cm x 3
cm
1
25 Relay cw 11 pin socket 10 A 240 Vac 2
26 Time delay relay 10 A 240 Vac 3
27 Triple pole Contactor 20A 240Vac 3
28 Batten type Lamp holder 240Vac 10 A 3
29 Start stop button 240Vac 10A 2
30 Indicating light (Bulb ) 240Vac 25W 3
31 Overload Relay 415V 20A 1
32 Three phase dahlander type
induction motor
5 hp 1
33 Single phase step down
transformer
24024Vac
2500VA
1
79 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
34 Single core PVC insulated
Cable
1mm 2 As required
35 Single core PVC insulated
Cable
25mm 2 As required
36 DIN rail 35 mm As required
37 PVC type Cable tray 50 mm x 50 mm As required
38 Cable ties 4 ldquo As required
39 Flexible wires 075 mm As required
40 PVC Connectors 5 A amp 20 A 240 V As required
41 Terminal block 20A 240Vac As required
Procedures
5 Identify each component according to specification and quantity required from the schematic
diagram attached
6 Test the functionality of each component by using multi-meter or power supply whichever
applicable
7 Wire component according to circuit diagram
8 Three motors operated in sequence by DOL starter operated by manual push button or time
delay relay
a One loop per-cycle
b Continuous operation in a loop
c optional circuit design to represent the same task
d Only one out of three motors to be operated at a time (quiz)
9 Test the functionality of completed project
80 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
BASIC DESIGN INDUSTRIAL MOTOR CONTROL (SEQUENCE CONTROL)
THREE PHASE INDUCTION MOTOR OPERATED IN SEQUENCE BY DIRECT ON LINE
STARTER
LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
81 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
82 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Lcd lamp indicator 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
11 Overload Relay 415V 20A 3
12 Three phase induction motor 5 hp 3
13 Single phase step down transformer 2500VA 1
14 Single core PVC insulated Cable 1mm 2 As required
15 Single core PVC insulated Cable 25mm 2 As required
16 DIN rail 35 mm As required
17 PVC type Cable tray 50 mm x 50 mm As required
18 Cable ties 4 ldquo As required
19 Flexible wires 1 mm Oslash As required
20 PVC Terminal block 10A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the schematic
diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a optional exercise
i Forward Reverse dahlander motor
4 Test the functionality of completed project
83 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
THREE PHASE DAHLANDER TYPE INDUCTION MOTOR OPERATED FORWARD AND
REVERSE OPERATION BY DIRECT ON LINE STARTER
84 ndash 99EASYTECH ENTERPRISE
LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
Introduction
If a motors windings are connected in the star configuration any two phases will be in series across
the supply and hence the line current will be smaller(by 577) than if the windings were connected in
the delta arrangement
Hence larger-type motors with heavy starting currents are first connected in star and then when the
starting currents fall in delta This of course means that all six of the ends of the windings must be
brought to terminations outside the casing (Fig 833)
EZTECH
EZTECH ELECTRICAL INSTALLATION GUIDE
The automatic version of this starter incorporates a timing relay which automatically changes the
connections from star to delta Figs 834 and 835 show the wiring and schematic diagrams for a star
delta starter
Objectives
1 Identify component and the specification
2 Design forward reverse star delta starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
2 ndash 99EASYTECH ENTERPRISE
REV -C
LEGENDMCCB Moulded Case Circuit BreakerTOR Thermal Over Load RelayFOW-C Mains Forward ContactorREV-C Mains Reverse ContactorDC Delta ContactorSC Star ContactorS-SW Mains Selector Switch
SC
V2
W2
U2
DC
V1
W1
U1
TOR
TOR
FOW-C
30A MCCB
TOR
MAIN CIRCUIT FORWARD REVERSE STAR DELTA
RYBN S
-SW
3 PHASEINDUCTION MOTOR
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Relay 10 A 240V 3
5 Triple pole Contactor
6 cw NO NC auxiliary contact
240Vac 20 A 4
7 Overload Relay 415 V 1
8 LED indicator 240vac 5 A 4
9 Start stop button 240Vac 5A 2
10 DIN rail 35 mm As required
11 Flexible wires 1 mm As required
12 Single core PVC insulated
wire
25 mm As required
13 Terminal block 20 A As required
14 Squirrel cage motor 5kW 1
15 5 pin plug and socket 415V 20A 1
16 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
3 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
a Manual star delta
b Manual Forward reverse star delta starter
c Automatic star delta starter
d Automatic Forward reverse star delta starter
4 Test the functionality of completed project
4 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
Objectives
1 Identify component and the specification
2 Design auto transformer starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
5 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Autotransformer starter is used to start a 3 phase induction motor that has a rating between 10 to 15 hp
6 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Autotransformer set 10Kw 415 V 50 Hz 1
5 Triple pole Contactor 240Vac 4
6 Batten type Lamp holder 240 Vac 105 A 4
7 Start stop button 240Vac 10A 4
8 Filament lamp (Bulb ) 240Vac 40W 4
9 DIN rail 35 mm As required
10 Flexible wires 1 mm As required
7 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
11 Single core PVC insulated
wire
25 mm As required
12 Terminal block 20 A As required
13 Squirrel cage motor 10kW 1
14 5 pin plug and socket 415V 20A 1
15 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a open transient autotransformer starter
b close transient autotransformer starter
c Forward reverse autotransformer starter
4 Test the functionality of completed project
8 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
Objectives
1 Identify component and the specification
2 Design rotor resistance starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
9 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Rotor Resistor set 10kW 1
5 Triple pole Contactor 240Vac 20A 4
6 Indicating light 240vac 5 A 4
7 Start stop push button 240Vac 5A 4
8 DIN rail 35 mm As required
9 Flexible wires 1 mm 2 As required
10 Single core PVC insulated wire 25 mm 2 As required
11 Terminal block 20 A As required
12 Slip Ring motor 10kW 1
13 5 pin round 3 phase socket 415V 20A 1
14 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
10 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
4 Test the functionality of completed project
a Dead circuit test b Life circuit test
5 Measure starting and running Amps
LESSON 16
TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
An installation in general will suffer damage
Damage usually occurs on the electric motor control as follows
1 Damage to the main circuit
2 Damage to the control circuit
The cause of the damage
i Overcurrent overload short circuit
ii Leakage current to ground
iii Equipment malfunction
iv The main control circuit
a Trip of main circuit protection devices fire
b Defect of motor terminal such as short circuit fire loose
v The control circuit is not functioning -
a contactor relay relay time overload relay does not work damaged burned
b Loose cable connection disconnected
Detecting and Repairing Damage
Examples of damage are as follows
i Motor does not work
ii Motor function and overload relay trips
iii Motor function but only partially functional control circuit
Methods of detecting damage
Among the known methods necessary to detect damage are as follows
1 Turn off the electricity at the main switch (main switch) in order to avoid any danger during the
work carried out to detect damage
2 Check all the protective gear that controls the motor control main circuit
11 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
3 Make sure the damage function control circuit
4 Check the control circuit according to the schematic circuit diagram of the motor control
5 Check the operation of the control circuit
Note
Use wiring that has been installed on the SYSTEM OF MOTOR CONTROL BOARD by Forward
Reverse control circuit for Star Delta to test and look for damage
SELF-ASSESSMENT QUESTIONS
1 (a) Explain what is meant by the term lsquoback emfrsquo in a motor
(b) Outline the basic differences between series shunt and compound wound dc motors
2 (a) With the aid of diagrams explain how the speed of series shunt and compound-wound motors
may be controlled
(b) A 440V dc shunt-wound motor has a field resistance of 200R and an armature resistance of 06 R
When its speed is 20 rev d second the current drawn from the supply is 122A Calculate its back
emf at this speed If the speed were decreased to 19 revssecond the field flux remaining unchanged
calculate the new back emf and the new armature current
3 A load of 64 kW at 240 V is supplied from the terminals of a shunt-wound dc generator The field
resistance is 180 A Calculate the armature current
4 (a) Explain with the aid of a diagram how a rotating magnetic field may be
(b) What is meant by lsquosynchronous speedrsquo
Calculate the synchronous obtained speed of a 12 pole motor if the supply frequency is 50Hz
5 (a) Explain the action of a synchronous motor
(b) What methods are available to start a synchronous motor Explain with diagrams
6 (a) Explain the action of a cage induction motor
(b) What is meant by the term lsquosliprsquo
Calculate the percentage slip of a six pole induction motor running at 162 revssecond from a 50 Hz
supply
7 Describe with sketches three different ways of starting a single-phase induction motor
12 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
8 Explain with the aid of a sketch the action of a three-phase DOL starter
What are dashpots used for How are remote start and stop buttons connected
9 A I0 kW 240V 50Hz single-phase cage rotor induction motor is 85efficient and has a PF of 068
lagging Calculate the motor current and the value of capacitor required to raise the PF to 093
lagging
10 Calculate the torque developed by an 18 kW four-pole induction motor run at 35 slip from a
50Hz supply
APPENDIX 1
13 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 11
14 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 111
Attachment Reference
httpswwwtlc-directcoukBook621htm
httpwwwstgovmyindexphpms
15 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
4 SAFETY REQUIREMENTS FOR ELECTRICAL WIRING WORKS IN RESIDENTIAL BUILDINGS
61 Safety Requirements
Safety requirements for electrical wiring works have to be followed to eliminate any accidents which
can result in physical damage or loss of life or property Failure to meet the safety regulations may
result in workers consumers or the public being inflicted with electrical shocks
In addition to this safety steps will also encourage workers or electricity consumers who are
disciplined and who always give importance to safety
62 Safety Steps
Safety requirements have to be followed whenever electrical works are undertaken in a residential
building
i Personal Safety
a Use suitable personal protection equipment as needed such as safety shoes gloves safety helmet
etc when at the work place
b Use safety clothing suitable for the work to be undertaken
c Do not wear jewellery or decorative items such as rings watches chains etc while carrying out
electrical works
ii Safety at the Work Place
a Acquire knowledge about the dangers of electrical works that is to be undertaken and how to deal
with those dangers
b Always adhere to the safety regulations which have been set for the work place
c Ensure that the electricity supply is switched off before carrying out the works
d Acquire the needed knowledge and practice a cautious and calm attitude while working ensure
cleanliness in and around fellow workers
e While working at elevated places the worker should always use suitable equipment such as wooden
or aluminium ladders iron scaffoldings or platforms safety belts or other equipment needed to ensure
that the work can be undertaken safely
f Use electrical equipment which is operational and safe to be used and ensure that the supply for it is
being supplied through a residual current device (RCD) with a sensitivity of 30 mA
g Ensure that exposed temporary supply electrical cables have mechanical protection
h If inflammable or corrosive material is present necessary safety steps have to be undertaken as
required by the relevant safety regulations
63 Dangers of Electrical Shocks
i Electrical Shock
Electrical shocks can occur due to direct or indirect contact
a Direct Contact
18 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Direct contact occurs when the worker or consumer receives an electrical shock on touching directly a
live conductor or cable
b Indirect Contact
Here the electric shock occurs due to contact with a part which is connected to the electrical
installation and not to a direct contact with a live cable or conductor possibly due to damages in the
appliance or insulation resulting in leakages of current
Why Electric Shocks Occura Unsafe Work Method or Action Undertaking Electrical Work Without Disconnecting the
Supply
Maintenance or circuit testing work done without disconnecting the supply will have a high possibility
of electrical shocks occurring
bull Not Following Safe Work Procedures
To eliminate the occurrence of electrical shocks each worker has to always follow safe work
procedures which are set by regulations and standards
b Defects in the Electrical System
i Leakage Current
Leakage currents or earth leakage currents can result in the metallic frames becoming live and
energised This can give rise to the danger of electrical shock to the worker consumer or the public if
they hold or come into contact with the metallic frame
ii Exposed Conductor or Disconnected Cable
Exposed conductors or cables which are broken and are alive (energised) can result in electrical shock
when touched The supply source must be immediately isolated or switched off and a report must be
made to the responsible entity
64 First Aid and Basic Pulmonary Resuscitation
i First Aid
First aid is the initial assistance given to a person who has met with an accident is sick or is injured to
prevent the condition of the victim from becoming more serious while awaiting the arrival of the
paramedics (ambulance) or before being brought to the hospital
i Pulmonary Resuscitation
Pulmonary resuscitation has to be undertaken to assist the victim who has breathing difficulties as a
result of being drowned receiving an electrical shock etc Pulmonary resuscitation has to be carried
out in accordance to the correct method as stated in the first aid manuals issued by accredited first aid
bodies
ii First Aid Box
19 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
A first aid box has to be provided by the building owner construction site supervisor or brought
personally by the worker under the supervision of the responsible person
65 Training Programme
The management shall conduct periodic training programmes for the workers with regards to work
safety on aspects including the following -
i Dangers of electrical work being undertaken and how to control those dangers
ii The safety regulations set for the work place and
iii First aid procedures
66 Fire Prevention
Fire Extinguisher A suitable functioning fire extinguisher to control fires has to be made available at
the work place at all times
67 Competent Person
The Electricity Regulations 1994 require that all electrical work has to be undertaken by or under the
direct supervision of a competent person registered with the Energy Commission Besides that the
electrical contractor undertaking the electrical work has also to be registered with the Energy
Commission The installation owner thus has to ensure that the appointed electrical contractor is
registered with the Energy Commission and that the registration is still valid
INSTALLATION CIRCUITS AND SYSTEMS1 Block diagrams
These show using squares rectangles etc the sequence of a system without too much technical detail
eg Figures 1517 and 1526
2 Layout diagrams
These are very similar to block diagrams but they indicate more technical detail and tend to show
items in their correct geographical location (eg Figures 1518 and 1519)
3 Circuitschematic
These show how a circuit functions and takes no account of exact locations of terminals or equipment
(eg Figures 1528 1529 1532 1534 etc)
4 Wiring diagram
These indicate how a circuit or system is physically wired (eg Figures 152 154 156 etc)
Most induction motors are started directly on line but when very large motors are started that way
they cause a disturbance of voltage on the supply lines due to large starting current surges To limit the
starting current surge large induction motors are started at reduced voltage and then have full supply
voltage reconnected when they run up to near rotated speed Two methods are used for reduction of
starting voltage are star delta starting and auto transformer stating
20 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Working Principal of Star-Delta Starter
This is the reduced voltage starting method Voltage reduction during star-delta starting is achieved by
physically reconfiguring the motor windings as illustrated in the figure below During starting the
motor windings are connected in star configuration and this reduces the voltage across each winding 3
This also reduces the torque by a factor of three After a period of time the winding are reconfigured as
delta and the motor runs normally
StarDelta starters are probably the most common reduced voltage starters They are used in
an attempt to reduce the start current applied to the motor during start as a means of reducing the
disturbances and interference on the electrical supply
Traditionally in many supply regions there has been a requirement to fit a reduced voltage
starter on all motors greater than 5HP (4KW) The StarDelta (or WyeDelta) starter is one of the
lowest cost electromechanical reduced voltage starters that can be applied
The StarDelta starter is manufactured from three contactors a timer and a thermal overload
The contactors are smaller than the single contactor used in a Direct on Line starter as they are
controlling winding currents only The currents through the winding are 1root 3 (58) of the
current in the line
There are two contactors that are close during run often referred to as the main contractor and
the delta contactor These are AC3 rated at 58 of the current rating of the motor The third
contactor is the star contactor and that only carries star current while the motor is connected in star
The current in star is one third of the current in delta so this contactor can be AC3 rated at one
third (33) of the motor rating
Star-delta Starter Consists following units
1) Contactors (Main star and delta contactors) 3 Norsquos (For Open State Starter) or 4 Norsquos (Close
Transient Starter)
2) Time relay (pull-in delayed) 1 No
3) Three-pole thermal over current release 1No
4) Fuse elements or automatic cut-outs for the main circuit 3 Nos
5) Fuse element or automatic cut-out for the control circuit 1No
Power Circuit of Star Delta Starter
1 The main circuit breaker serves as the main power supply switch that supplies electricity to the
power circuit
2 The main contactor connects the reference source voltage R Y B to the primary terminal of the
motor U1 V1 W1
21 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
3 In operation the Main Contactor (KM3) and the Star Contactor (KM1) are closed initially and
then after a period of time the star contactor is opened and then the delta contactor (KM2) is
closed The control of the contactors is by the timer (K1T) built into the starter The Star and Delta
are electrically interlocked and preferably mechanically interlocked as well In effect there are
four states
4 The star contactor serves to initially short the secondary terminal of the motor U2 V2 W2 for the
start sequence during the initial run of the motor from standstill This provides one third of DOL
current to the motor thus reducing the high inrush current inherent with large capacity motors at
startup
5 Controlling the interchanging star connection and delta connection of an AC induction motor is
achieved by means of a star delta or wye delta control circuit The control circuit consists of push
button switches auxiliary contacts and a timer
Control Circuit of Star-Delta Starter (Open Transition)
1 The ON push button starts the circuit by initially energizing Star Contactor Coil (KM1) of star
circuit and Timer Coil (KT) circuit
2 When Star Contactor Coil (KM1) energized Star Main and Auxiliary contactor change its
position from NO to NC
3 When Star Auxiliary Contactor (1)( which is placed on Main Contactor coil circuit )became
NO to NC itrsquos complete The Circuit of Main contactor Coil (KM3) so Main Contactor Coil
energized and Main Contactorrsquos Main and Auxiliary Contactor Change its Position from NO
To NC This sequence happens in a friction of time
4 After pushing the ON push button switch the auxiliary contact of the main contactor coil (2)
which is connected in parallel across the ON push button will become NO to NC thereby
providing a latch to hold the main contactor coil activated which eventually maintains the
control circuit active even after releasing the ON push button switch
5 When Star Main Contactor (KM1) close its connect Motor connects on STAR and itrsquos
connected in STAR until Time Delay Auxiliary contact KT (3) become NC to NO
6 Once the time delay is reached its specified Time the timerrsquos auxiliary contacts (KT)(3) in
Star Coil circuit will change its position from NC to NO and at the Same Time Auxiliary
contactor (KT) in Delta Coil Circuit(4) change its Position from NO To NC so Delta coil
energized and Delta Main Contactor becomes NO To NC Now Motor terminal connection
change from star to delta connection
7 A normally close auxiliary contact from both star and delta contactors (5amp6)are also placed
opposite of both star and delta contactor coils these interlock contacts serves as safety
switches to prevent simultaneous activation of both star and delta contactor coils so that one
22 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
cannot be activated without the other deactivated first Thus the delta contactor coil cannot be
active when the star contactor coil is active and similarly the star contactor coil cannot also
be active while the delta contactor coil is active
8 The control circuit above also provides two interrupting contacts to shutdown the motor
The OFF push button switch break the control circuit and the motor when necessary The
thermal overload contact is a protective device which automatically opens the STOP Control
circuit in case when motor overload current is detected by the thermal overload relay this is to
prevent burning of the motor in case of excessive load beyond the rated capacity of the motor
is detected by the thermal overload relay
9 At some point during starting it is necessary to change from a star connected winding to a
delta connected winding Power and control circuits can be arranged to this in one of two
ways ndash open transition or closed transition
What is Open or Closed Transition Starting
(1) Open Transition Starters
Discuss mention above is called open transition switching because there is an open state between
the star state and the delta state
In open transition the power is disconnected from the motor while the winding are reconfigured via
external switching
When a motor is driven by the supply either at full speed or at part speed there is a rotating
magnetic field in the stator This field is rotating at line frequency The flux from the stator field
induces a current in the rotor and this in turn results in a rotor magnetic field
When the motor is disconnected from the supply (open transition) there is a spinning rotor within
the stator and the rotor has a magnetic field Due to the low impedance of the rotor circuit the time
constant is quite long and the action of the spinning rotor field within the stator is that of a
generator which generates voltage at a frequency determined by the speed of the rotor When the
motor is reconnected to the supply it is reclosing onto an unsynchronized generator and this result
in a very high current and torque transient The magnitude of the transient is dependent on the
phase relationship between the generated voltage and the line voltage at the point of closure can
be much higher than DOL current and torque and can result in electrical and mechanical damage
Open transition starting is the easiest to implement in terms or cost and circuitry and if the timing
of the changeover is good this method can work well In practice though it is difficult to set the
necessary timing to operate correctly and disconnectionreconnection of the supply can cause
significant voltagecurrent transients
In Open transition there are Four states
23 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 OFF State All Contactors are open
2 Star State The Main [KM3] and the Star [KM1] contactors are closed and the delta [KM2]
contactor is open The motor is connected in star and will produce one third of DOL torque at one
third of DOL current
3 Open State This type of operation is called open transition switching because there is an
open state between the star state and the delta state The Main contractor is closed and the Delta
and Star contactors are open There is voltage on one end of the motor windings but the other end
is open so no current can flow The motor has a spinning rotor and behaves like a generator
4 Delta State The Main and the Delta contactors are closed The Star contactor is open The
motor is connected to full line voltage and full power and torque are available
(2) Closed Transition StarDelta Starter
There is a technique to reduce the magnitude of the switching transients This requires the use of a
fourth contactor and a set of three resistors The resistors must be sized such that considerable
current is able to flow in the motor windings while they are in circuit
The auxiliary contactor and resistors are connected across the delta contactor In operation just
before the star contactor opens the auxiliary contactor closes resulting in current flow via the
resistors into the star connection Once the star contactor opens current is able to flow round
through the motor windings to the supply via the resistors These resistors are then shorted by the
delta contactor If the resistance of the resistors is too high they will not swamp the voltage
generated by the motor and will serve no purpose
In closed transition the power is maintained to the motor at all time This is achieved by
introducing resistors to take up the current flow during the winding changeover A fourth
contractor is required to place the resistor in circuit before opening the star contactor and then
removing the resistors once the delta contactor is closed These resistors need to be sized to carry
the motor current In addition to requiring more switching devices the control circuit is more
complicated due to the need to carry out resistor switching
In Close transition there are Four states
1 OFF State All Contactors are open
2 Star State The Main [KM3] and the Star [KM1] contactors are closed and the delta [KM2]
contactor is open The motor is connected in star and will produce one third of DOL torque at one
third of DOL current
Star Transition State The motor is connected in star and the resistors are connected across the
delta contactor via the aux [KM4] contactor
24 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Closed Transition State The Main [KM3] contactor is closed and the Delta [KM2] and Star
[KM1] contactors are open Current flows through the motor windings and the transition resistors
via KM4
Delta State The Main and the Delta contactors are closed The transition resistors are shorted out
The Star contactor is open The motor is connected to full line voltage and full power and torque
are available
Effect of Transient in Starter (Open Transient starter)
It is Important the pause between star contactor switch off and Delta contactor switch is on correct
This is because Star contactor must be reliably disconnected before Delta contactor is activated It
is also important that the switch over pause is not too long
For 415v Star Connection voltage is effectively reduced to 58 or 240v The equivalent of 33
that is obtained with Direct Online (DOL) starting
If Star connection has sufficient torque to run up to 75 or 80 of full load speed then the motor
can be connected in Delta mode
When connected to Delta configuration the phase voltage increases by a ratio of V3 or 173 The
phase currents increase by the same ratio The line current increases three times its value in star
connection
During transition period of switchover the motor must be free running with little deceleration
While this is happening ldquoCoastingrdquo it may generate a voltage of its own and on connection to the
supply this voltage can randomly add to or subtract from the applied line voltage This is known as
transient current Only lasting a few milliseconds it causes voltage surges and spikes Known as
a changeover transient
Size of each part of Star-Delta starter
(1) Size of Over Load Relay
For a star-delta starter there is a possibility to place the overload protection in two positions in the
line or in the windings
Overload Relay in Line
In the line is the same as just putting the overload before the motor as with a DOL starter
The rating of Overload (In Line) = FLC of Motor
Disadvantage If the overload is set to FLC then it is not protecting the motor while it is in delta
(setting is x1732 too high)
Overload Relay in Winding
25 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
In the windings means that the overload is placed after the point where the wiring to the contactors
are split into main and delta The overload then always measures the current inside the windings
The setting of Overload Relay (In Winding) =058 X FLC (line current)
Disadvantage We must use separate short circuit and overload protections
(2) Size of Main and Delta Contractor
1 There are two contactors that are close during run often referred to as the main contractor and
the delta contactor These are AC3 rated at 58 of the current rating of the motor
Size of Main Contactor= IFL x 058
(3) Size of Star Contractor
The third contactor is the star contactor and that only carries star current while the motor is
connected in star The current in star is 1 radic3= (58) of the current in delta so this contactor can
be AC3 rated at one third (33) of the motor rating
Size of Star Contactor= IFL x 033
Motor Starting Characteristics of Star-Delta Starter
Available starting current 33 Full Load Current
Peak starting current 13 to 26 Full Load Current
Peak starting torque 33 Full Load Torque
Advantages of Star-Delta starter
The operation of the star-delta method is simple and rugged
It is relatively cheap compared to other reduced voltage methods
Good TorqueCurrent Performance
It draws 2 times starting current of the full load ampere of the motor connected
Disadvantages of Star-Delta starter
Low Starting Torque (Torque = (Square of Voltage) is also reduce)
Break In Supply ndash Possible Transients
Six Terminal Motor Required (Delta Connected)
It requires 2 set of cables from starter to motor
It provides only 33 starting torque and if the load connected to the subject motor requires higher
starting torque at the time of starting than very heavy transients and stresses are produced while
changing from star to delta connections and because of these transients and stresses many
electrical and mechanical break-down occurs
26 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
In this method of starting initially motor is connected in star and then after change over the motor
is connected in delta The delta of motor is formed in starter and not on motor terminals
High transmission and current peaks When starting up pumps and fans for example the load
torque is low at the beginning of the start and increases with the square of the speed When
reaching approx 80-85 of the motor rated speed the load torque is equal to the motor torque and
the acceleration ceases To reach the rated speed a switch over to delta position is necessary and
this will very often result in high transmission and current peaks In some cases the current peak
can reach a value that is even bigger than for a DOL start
Applications with a load torque higher than 50 of the motor rated torque will not be able to start
using the start-delta starter
Low Starting Torque The star-delta (wye-delta) starting method controls whether the lead
connections from the motor are configured in a star or delta electrical connection The initial
connection should be in the star pattern that results in a reduction of the line voltage by a factor of
1radic3 (577) to the motor and the current is reduced to 13 of the current at full voltage but the
starting torque is also reduced 13 to 15 of the DOL starting torque
The transition from star to delta transition usually occurs once nominal speed is reached but is
sometimes performed as low as 50 of nominal speed which make transient Sparks
Features of star-delta starting
1 For low- to high-power three-phase motors
2 Reduced starting current
3 Six connection cables
4 Reduced starting torque
5 Current peak on changeover from star to delta
6 Mechanical load on changeover from star to delta
Application of Star-Delta Starter
The star-delta method is usually only applied to low to medium voltage and light starting
Torque motors
The received starting current is about 30 of the starting current during direct on line start and the
starting torque is reduced to about 25 of the torque available at a DOL start This starting
method only works when the application is light loaded during the start If the motor is too heavily
27 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
loaded there will not be enough torque to accelerate the motor up to speed before switching over
to the delta position
LESSON 1 WIRING SYSTEM OF SINGLE PHASE DISTRIBUTION BOARD
Introduction
28 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
29 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
30 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
31 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 2 WIRING SYSTEM OF SINGLE PHASE LIGHTING CIRCUIT Introduction
Objectives
1 Identify component and the specification
2 Wire component according to the schematic diagram
3 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Wiring bay Perforated metal 180 cm x 180 cm 1
2 Cut out fuse 63 A 240 V 1
3 Neutral link 1
4 Single pole one way switch cw
switch box
5A 240Vac 4
5 single pole two way switch cw
switch box
5A 240Vac 2
6 RCCB In = 40 A Tripping current
100mA240 Vac 50 Hz
1
7 Main switch 32 A 240V 1
8 kWatthour meter 40 A 240 Vac 1
9 Single pole MCB 6A 240 Vac 1
10 Self tapping Wood screw As required
11 DIN rail 35 mm width As required
32 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
12 PVC trunking 50 mm x 50 mm As required
13 Terminal blocks 5 A As required
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
1 One way switch to control one lamp
2 One way switch to control two lamps
3 Two of two way switch to control one lamp
4 Two of single pole two way switch and one of an intermediate switch to control one
lamp
5 One unit of ceiling fan and fan regulator to be controlled by one way switch
4 Test the functionality of completed project
LESSON 3ndash WIRING SYSTEM OF SINGLE PHASE POWER CIRCUIT Introduction
33 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
34 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify types of component and its specification
2 Wire component according to the schematic diagram given
3 Test the functionality of the circuit dead circuit test life circuit test
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board Perforated Metal 1
2 kWh meter 240 V 40 A 1
3 Socket outlet 13A 240Vac 4
4 RCCB 40A Trip Amps
30mA240 Vac
1
5 3 pin socket 240Vac 13A 4
6 Single pole MCB 20A 240 V 2
7 DOL starter 1 kW 240Vac 2
8 1 phase induction motor 2Hp 240 Vac 1
9 Cooker control unit 4kW 240Vac 1
10 Water heater point 4kW 240 Vac 1
11 DIN rail 35 mm As required
12 PVC casing 20mm As required
13 Flexible wires 05 mm As required
14 Terminal block 10 A As required
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Wire two unit of 13 A socket outlet in radial circuit
3 Wire four units of 13 A socket outlet in ring circuit
4 Wire one unit DOL starter for air-conditioner point
5 Wire one unit of cooker control unit point
6 Wire one unit of water heater point
7 Test the functionality of each component by using mmeter or power supply whichever
applicable
8 Wire component according to circuit diagram
9 Test the functionality of completed project dead circuit test life circuit test
Note
35 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Ensure that the correct rating of protection device and size of wire used
LESSON 4ndash CONDUIT BENDING AND TRUNKING FABRICATION TECHNIQUE
Common fitting used in an industrial wiring
Cutting and threading the condute
36 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
37 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
38 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify conduit fitting and the specification
2 Measure and Cut steel conduit according to specified dimension
3 Bend and fabricate conduit at 45 90 according to layout diagram
4 Wire component according to the schematic diagram
5 Test the functionality of the circuit
39 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Conduit Bender Oslash 19 mm ( frac34 ldquo) 1
2 Measuring Tape 3 metre 1
3 Hacksaw frame and blade 30cm 1
4 Conduit cutter 1
5 Pipe Vise 1
6 Pipe Wrench 1
7 Ratchet Dies 20 mm 1
8 Metal trunking 50 mm x 50 mm 1
9 GI conduit 20mm 1
10 End box 20 mm 1
11 Flexible wires 05 mm As required
12 Connectors 5 A As required
13 Single core PVC ins Cable 25 mm 2 As required
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Wire two unit of 13 A socket outlet in radial circuit
3 Wire four unit of 13 A socket outlet in ring circuit
4 Wire one unit DOL starter for air-conditioner point
5 Wire one unit of cooker control unit point
6 Wire one unit of water heater point
7 Test the functionality of each component by using multimeter or power supply whichever
applicable
8 Wire component according to circuit diagram
9 Test the functionality of completed project
Note
Ensure that the rating of protection device and size of wire
K prior to 31 March
2004 (BS 7671)
(formerly)
bare conductor
sleeved at terminations (formerly)
40 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 5 ndashWIRING SYSTEM OF 1 Oslash LIGHTING AND POWER CIRCUIT
POWER CIRCUITSa Radial circuits
Radial circuits are arranged in the same way as item 1 above in lighting layouts in that each socket
outlet is supplied via the previous one
Points to note
1 The number of socket outlets complying with BS 1363 is unlimited for a floor area of up to 50m 2 if
the circuit protection is a 30 A or 32 A cartridge fuse or circuit breaker the cable being 4 mm PVC
copper or 25 mm2 mineral insulated (mi)
2 The number of socket outlets is unlimited for a floor area up to 20 m 2 with any type of circuit
protection of 20 A using 25 mm2 PVC copper cable or 15 mm2 mi
3 The total number of fused spurs is unlimited
b ring final circuits
These circuits are the same as radial circuits except that the final socket outlet is wired back to the
supply position In effect any outlet is supplied from two directions (Fig 152)
Points to note
1 Every twin-socket outlet counts as two single-socket outlets
2 The number of non-fused spurs must not exceed the total number of points on the ring Fig 158
shows seven points on the ring and five spurs
3 The fuse rating of a fused spur box must not exceed 13 A and the current rating of all points supplied
by the fused spur must not exceed 13 A
4 Non-fused spurs must supply no more than one single or one double socket on the ring Fig 158
shows seven points on the ring and five spurs rating of all points supplied by the fused spur must not
exceed 13 A or one stationary appliance
CapacityMain conductor size
copper (mm2)
Earth conductor
size (mm2)
Circuit breaker
capacity (A)
Up to 600 W 15 15 6
600ndash1200 W 1525 15 10
1200ndash1800 W 254 25 16
41 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Ring circuit
(floor area 100 m2)25 15 3032
A2 radial circuit
(floor area 75 m2)40 25 3032
A3 radial circuit
(floor area 50 m2)25 15 20
Air conditioner (15 tonne) 60 60 3032
Cooker 60 60 3032
Water heater 40 40 20
Objectives
1 Identify component and the specification
2 Wire component according to the schematic diagram
3 Test the functionality of the circuit
42 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board Perforated 1
2 Cut out fuse and neutral link 60A 240V 1each
3 kWh meter 240V 40A 1
4 Switched Socket outlet 13A 240Vac 4
5 Single pole two way switch cw switch
box
5A 240Vac 2
6 RCCB ELCB 63 A Tripping current 100mA
415 Vac
1
7 3 pin plug 240Vac 13A 4
8 Single pole MCB 20 A 2
9 Single pole MCB 6A 1
10 Single pole MCB 20A 2
11 DOL starter 240Vac 2
12 1 phase induction motor 2hp 240 Vac 1
13 Self tapping Wood screw As required
14 DIN rail Stainless steel allum35 mm As required
15 PVC pipe 20mm dia As required
16 End box 20 mm dia 4
17 Flexible wires 05 mm 2 As required
18 Connectors 5 A As required
Procedures
43 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
4 Test the functionality of completed project
LESSON 6 ndash WIRING SYSTEM OF 3 Oslash DISTRIBUTION BOARD
Introduction
44 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
45 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
46 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
47 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
48 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify each component and the specification
2 Wire component according to the schematic diagram given
3 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting Board 450 x 600 mm Perforated metal 1
2 5 pin round socket and plug 415V ac 32A 1
3 Cut out fuse 60 A 3
4 Neutral link 1
5 kWatt hour meter 415V 60A 1
6 ELCB RCCB 3P+N In=63A415 Vac I trip= 300mA 1
7 ELCB RCCB 3P+N In=63A415 Vac I trip= 30mA 1
8 Single pole MCB 6A 240 V 3
9 Single pole MCB 20A 240 V 3
10 DOL starter 20 A 240Vac 2
11 Socket outlet 15 A 240 Vac 1
12 Switched Socket outlet 13 A 240 Vac 3
13 Led indicating light 5A 240 Vac 3
14 Single pole 4 gang 1 way switch 5A 240 Vac 2
15 Single pole 2 way switch 5A 240 Vac 2
16 1 phase induction motor 1 kW 240Vac 1
17 Metal trunking 30 mm x30 mm As required
18 Self tapping Wood screw 4 mm x 20 mm As required
19 DIN rail 25 mm x 1mm
20 GI steel rigid conduit 20mm As required
21 Flexible conduit 20mm As required
22 End box 20 mm 4
23 Flexible wires 05 mm 2 As required
24 Single core PVC insulated wire 15 mm 2 As required
25 Single core PVC insulated wires 25 mm 2 As required
26 Terminal block 10 A As required
Procedures
49 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify each components and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
4 Test the functionality of completed project
1 dead circuit test
2 life circuit
Note Proper earthing should be made
50 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 7 ndash WIRING SYSTEM OF THREE PHASE LIGHTING AND POWER CIRCUIT
51 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
52 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify component and the specification
2 Wire component according to the schematic diagram
3 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting bay Board Perforated metal 180 cm x 180 cm 1
2 k Watt hour meter 415V 60A 1
3 MCCB 415V 60A
4 ELCB RCCB In=60A415 Vac I trip=30mA 1
5 5 pin round Socket and
plug
415Vac 32A 4
6 Single pole MCB 6A 1
7 Triple pole MCB 20A 2
8 Triple pole Main switch 60A 1
9 DOL starter 240Vac 2
10 3 phase induction motor 2hp 415 Vac 1
11 1 phase induction motor 1
12 Metal trunking 30 mm x30 mm As required
13 Self tapping Wood screw 4 mm x 20 mm As required
14 DIN rail 25 mm x 1mm
15 GI steel rigid conduit 20mm As required
16 Flexible conduit 20mm As required
17 End box 20 mm 4
18 Flexible wires 05 mm As required
19 Connectors 10 A As required
Procedures
1 Identify each components and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
4 Test the functionality of completed project
1 dead circuit 2 life circuit test
5 Record the current drawn by the load as connected in star and delta
Note Proper earthing should be made
53 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 8 INSPECTION AND TESTING OF ELECTRICAL INSTALLATION
On completion of a wiring installation a number of tests on the installation have to be conducted to
ascertain that the wiring circuits and connected appliances are safe for use Prior to carrying out the
tests an inspection has to be done The results of the inspectionsupervision and test have to be
presented in Form G (as in Appendix IV) and Form H (as in Appendix V)
To have the test certification as in Form H the following tests shall be conducted
i Continuity Test
ii Insulation Resistance Test
iii Polarity Test
iv Earth Electrode Resistance test and
v Residual Current Device Test
1 Continuity Test
There are 3 main types of continuity tests for the final circuits-
i Protection Conductor Continuity Test
ii Final Ring Circuit Conductor Continuity Test
iii Live and Neutral Conductor Continuity Test
a) Protection Conductor Continuity Test
bull To ascertain that all protection conductors are connected in the correct and effective manner
bull Test equipment ndash Multimeter (Ohm range) or Ohm meter
54 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
bull Test Method
1 1048766 Ensure that the main switch RCD and MCB are open circuited (switched off) and all loads
are disconnected
2 1048766 Connected the test leads as in the Figure 81 The meter reading shall be less than 1 Ω
55 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Final Ring Circuit Conductor Continuity Test
bull To ensure that all conductors around the ring circuit have continuity
bull Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
bull Test Method
1 1048766 Disconnect both the supply source live conductors from the MCB the neutral conductor
from the neutral terminals and the earth conductor from the earth terminal in the distribution
fuse box
2 1048766 Connect the test leads as in the Figure 82 (EE)
3 1048766 Repeat the procedure for (L-L) and (N-N)
4 1048766 The meter reading value shall be less than 1 ohm
56 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Live and Neutral Conductor Continuity Test
a To ensure that each conductor in the circuit has continuity
b Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
2 Test Method
1 1048766 Switch off the Main switch RCD and MCB
2 1048766 Disconnect all loads
3 1048766 Switch on all switches in the circuit
4 1048766 Disconnect the fusesfinal circuit breakers and close the circuit
5 1048766 Carry out the test as shown in Figure 83
6 1048766 The meter reading value shall be less than 1Ω
57 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
58 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
CONTINUITY TEST
Insulation Resistance Test
i Ensure that there is no leakage current between phase conductors phase and neutral conductors and
phase conductor and earth
ii Test the strength of the cable insulation
iii Test Equipment ndash Insulation Resistance Tester operating voltage is 250VDC or 500VDC
iv Test Method
1 1048766 Switch off main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
59 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
4 1048766 Carry out test as in the Table below
5 1048766 Meter reading value shall be less than 1 Megaohm
60 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
61 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Insulation resitance test
62 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
INSULATION RESISTANCE TEST BETWEEN CONDUCTORS AND OPPOSITE POLARITY
Polarity Testi Ensure that each fuse or single pole control and protection device is connected only in the phase
conductor
ii Intermediate contact of Edison screw lamp holder is connected to the phase conductor
iii Ensure that phase neutral and earth conductors at socket outlets are connected at the correct
terminals
iv Test Equipment ndash Multimeter (Ohm range) or Ohm meter
v Test Method
1 1048766 Switch off Main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in Figure 85
63 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
5 1048766 Test switches and single phase control devices at the phase conductors
6 1048766 Test socket outlet connection sources
7 1048766 Test Edison screw lamp holder connections
8 1048766 Meter reading value shall be less than 1 Ω
64 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Polarity test
65 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Earth Electrode Resistance Testi To test the earth electrode resistance
ii To ascertain the suitability of the location of the electrode
iii To ensure that the electrode is not buried within the resistance area of another electrode
iv Test equipment ndash Earth Resistance Tester
v Test method -
1 1048766 Terminal rsquoErsquo is connected to the electrode to be tested (green conductor)
2 1048766 Terminal lsquoPrsquo is connected to the potential spike (yellow conductor) at a distance of 10
meters from the earth electrode
3 1048766 Terminal lsquoCrsquo is connected to the current spike (red conductor) at a distance of 20 meters
from the earth electrode
Earth Electrode Resistance Measurement Method (Figure 86)
This test must be repeated at least three times to ensure that the reading is not affected by interacting
earthing regions
i Record the first reading (Z1) Example Z1 = 10 Ω
ii Move the voltage spike to a distance of 6 meters from the original position Record the second
reading (Z2 ) Example Z2 = 10 Ω
iii Move the voltage spike to a distance of 6 meters from the original position Record the third
reading (Z3) Example Z3 = 10 Ω
66 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Residual Current Device Testi Ensure that the residual current device (RCD) trips within the set time on the occurrence of current
leakage to earth
ii Test Equipment ndash RCD Tester RCCB Tester
iii Test Method 1
1 1048766 Use the Trip Test Button
2 1048766 Press the trip button found on the RCD to determine if it trips or otherwise This test would
not be able to determine the sensitivity of the RCD nor the time taken for it to trip
iv Test Method 2
i 1048766 Use a RCD Tester
ii This equipment is equipped with a 13A plug which can be connected to a 13A socket outlet
Select the RCD sensitivity to be the same as the sensitivity of the RCD to be tested to
determine if the RCD can trip The time to trip shall not exceed 40 mS
iii 1048766 Test method ndash
a) Position the selection switch in accordance with the sensitivity of the RCD used
Example 100 mA 01 A
b) Position the operations switch to lsquoNo Triprsquo (frac12 Rated mA = 50) connect the 3 pin plug to
the 13A socket outlet
67 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
c) Switch on the 13A socket outlet ndash ensure that the P-N and P-E lights light up
This shows that the polarity is correct (Note if both the lights as above do not light up the test cannot
be continued)
d) Press the test button ndash the reading shows less than 200 mS and simultaneously the lsquotestrsquo light lights
up and the P-N and P-E lights do not light up At that instant the RCD will not trip
e) Move the selection switch to 180o (+ve wave) ndash repeat steps (d) and (e) Move the operations
switch to lsquoTriprsquo (Rated mA = 100)
g) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200mS
h) Move the selection switch to 0o (-ve wave)
i) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
j) The above test is repeated until a near correct reading is obtained
k) Record the test results
l) Change the operations switch to lsquoFast Triprsquo and press the test button ndash RCD will trip within a
time not exceeding 40 millisecond
m) Repeat a number of times at 0o or 180o
On completion of a wiring installation a number of tests on the installation have to be conducted to
ascertain that the wiring circuits and connected appliances are safe for use Prior to carrying out the
tests an inspection has to be done the following tests shall be conducted
i Continuity Test
ii Insulation Resistance Test
iii Polarity Test
iv Earth Electrode Resistance test and
v Residual Current Device Test
821 Continuity Test
There are 3 main types of continuity tests for the final circuits-
i Protection Conductor Continuity Test
ii Final Ring Circuit Conductor Continuity Test
68 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
iii Live and Neutral Conductor Continuity Test
a) Protection Conductor Continuity Test
bull To ascertain that all protection conductors are connected in the correct and effective manner
bull Test equipment ndash Multimeter (Ohm range) or Ohm meter
bull Test Method
1 1048766 Ensure that the main switch RCD and MCB are open circuited (switched off) and all loads are
disconnected
2 1048766 Connected the test leads as in the Figure 81
3 1048766 The meter reading shall be less than 1 Ω
Final Ring Circuit Conductor Continuity Test
bull To ensure that all conductors around the ring circuit have continuity
bull Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
bull Test Method
1 1048766 Disconnect both the supply source live conductors from the MCB the neutral conductor
from the neutral terminals and the earth conductor from the earth terminal in the distribution
fuse box
2 1048766 Connect the test leads as in the Figure 82 (EE)
3 1048766 Repeat the procedure for (L-L) and (N-N)
4 1048766 The meter reading value shall be less than 1 ohm Figure 82 - Final Ring Circuit Conductor
Continuity Test Ohm Meter
Disconnect both the supply source cables from mcbfuse
Take readings at earth conductors of both sources and note resistance readings
Live and Neutral Conductor Continuity Test
1 To ensure that each conductor in the circuit has continuity
2 Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
3 Test Method
1 1048766 Switch off the Main switch RCD and MCB
2 1048766 Disconnect all loads
3 1048766 Switch on all switches in the circuit
4 1048766 Disconnect the fusesfinal circuit breakers and close the circuit
5 1048766 Carry out the test as shown in Figure 83
6 1048766 The meter reading value shall be less than 1 ohm Figure 83 - Live and Neutral
Conductor Continuity Test Ohm Meter
Insulation Resistance Test
69 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
i Ensure that there is no leakage current between phase conductors phase and neutral conductors and
phase conductor and earth
ii Test the strength of the cable insulation
iii Test Equipment ndash Insulation Resistance Tester Operating voltage is 250VDC or 500VDC
iv Test Method
1 1048766 Switch off main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in the Table below
5 1048766 Meter reading value shall be less than 1 Megaohm
Polarity Test
i Ensure that each fuse or single pole control and protection device is connected only in the phase
conductor
ii Intermediate contact of Edison screw lamp holder is connected to the phase conductor
iii Ensure that phase neutral and earth conductors at socket outlets are connected at the correct
terminals
iv Test Equipment ndash Multimeter (Ohm range) or Ohm meter
v Test Method
1 1048766 Switch off Main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in Figure 85
5 1048766 Test switches and single phase control devices at the phase conductors
6 1048766 Test socket outlet connection sources
7 1048766 Test Edison screw lamp holder connections
8 1048766 Meter reading value shall be less than 1 Ω
Earth Electrode Resistance Test
i To test the earth electrode resistance
70 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
ii To ascertain the suitability of the location of the electrode
iii To ensure that the electrode is not buried within the resistance area of another electrode
iv Test equipment ndash Earth Resistance Tester
v Test method -
1 1048766 Terminal rsquoErsquo is connected to the electrode to be tested (green conductor)
2 1048766 Terminal lsquoPrsquo is connected to the potential spike (yellow conductor) at a distance of 10
meters from the earth electrode
3 1048766 Terminal lsquoCrsquo is connected to the current spike (red conductor) at a distance of 20 meters
from the earth electrode E P C Electrode 10 meter 10 meter
Figure 86 ndash Earth Electrode Resistance Measurement Test Equipment
Earth Electrode Resistance Measurement Method (Figure 86)
This test must be repeated at least three times to ensure that the reading is not affected by interacting
earthing regions
i Record the first reading (Z1) Example Z1 = 10 Ω
ii Move the voltage spike to a distance of 6 meters from the original position Record the second
reading (Z2) Example Z2 = 10 Ω
iii Move the voltage spike to a distance of 6 meters from the original position Record the third
reading (Z3)
Example Z3 = 10 Ω
Residual Current Device Test
71 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
i Ensure that the residual current device (RCD) trips within the set time on the occurrence of current
leakage to earth
ii Test Equipment ndash RCD Tester RCCB Tester
iii Test Method 1
1 1048766 Use the Trip Test Button
2 1048766 Press the trip button found on the RCD to determine if it trips or otherwise This test would
not be able to determine the sensitivity of the RCD nor the time taken for it to trip
iv Test Method 2
1048766 Use a RCD Tester
This equipment is equipped with a 13A plug which can be connected to a 13A socket outlet Select the
RCD sensitivity to be the same as the sensitivity of the RCD to be tested to determine if the RCD can
trip The time to trip shall not exceed 40 mS
1048766 Test method ndash
a) Position the selection switch in accordance with the sensitivity of the RCD used
Example 100 mA 01 A
b) Position the operations switch to lsquoNo Triprsquo (frac12 Rated mA = 50) connect the 3 pin plug to
the 13A socket outlet
c) Switch on the 13A socket outlet ndash ensure that the P-N and P-E lights light up This shows that
the polarity is correct (Note if both the lights as above do not light up the test cannot be
continued)
d) Press the test button ndash the reading shows less than 200 millisecond and simultaneously the
lsquotestrsquo light lights up and the P-N and P-E lights do not light up At that instant the RCD will
not trip
e) Move the selection switch to 180o (+ve wave) ndash repeat steps (d) and (e) = 100)
f) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
g) Move the selection switch to 0o (-ve wave)
h) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
i) The above test is repeated until a near correct reading is obtained
j) Record the test results
k) Change the operations switch to lsquoFast Triprsquo and press the test button ndash RCD will trip within a
time not exceeding 40 mS
l) Repeat a number of times at 0o or 180o
72 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 9 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (DC)
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
73 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Start stop button 240Vac 5A 2
9 Filament lamp (Bulb ) 240Vac 40W 3
10 Overload Relay 415V 20A 3
11 Three phase induction motor 5 hp 3
12 Single phase step down transformer 2500VA 1
13 Single core PVC insulated Cable 1mm 2 As required
14 Single core PVC insulated Cable 25mm 2 As required
15 DIN rail 35 mm As required
16 PVC type Cable tray 50 mm x 50 mm As required
17 Cable ties 4 ldquo As required
18 Flexible wires 05 mm As required
19 PVC Connectors 5 A amp 20 A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the schematic
diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a optional exercise
i Simple DOL starter
ii Forward reverse DOL starter
iii Forward Reverse Dahlander motor
iv Three motors operated in sequence by DOL starter operated by manual push
button or time delay relay
74 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
a One loop per-cycle
b Continuous operation in a loop
c optional circuit design to represent the same task
v Only one out of three motors to be operated at a time (quiz)
4 Test the functionality of completed project
LESSON 10 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (AC)
75 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 1
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Lamp point 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
76 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
11 Overload Relay 415V 20A 3
12 Three phase induction
motor
5 hp 3
13 Single core PVC insulated
Cable
1mm 2 As required
14 Single core PVC insulated
Cable
25mm 2 As required
15 DIN rail 35 mm As required
16 PVC type Cable tray 50 mm x 50 mm As required
17 Cable ties 4 ldquo As required
18 Flexible wires 05 mm As required
19 PVC Connectors 5 A amp 20 A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the
schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram optional exercise
4 Simple DOL starter
5 Forward reverse DOL starter
6 Test the functionality of completed project
77 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 1
78 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
cm
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Indicating light 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
11 Overload Relay 415V 20A 3
12 Three phase induction motor 5 hp 3
13 Single phase step down
transformer
2500VA 1
14 Single core PVC insulated
Cable
1mm 2 As required
15 Single core PVC insulated
Cable
25mm 2 As required
16 DIN rail 35 mm As required
17 PVC type Cable tray 50 mm x 50 mm As required
18 Cable ties 4 ldquo As required
19 Flexible wires 05 mm As required
20 PVC Connectors 5 A amp 20 A 240 V As required
21 Single pole MCB 6A 240 V 1
22 Single pole MCB 2A 240 V 1
23 Triple pole MCB 20A 415 V 1
24 Mounting board 30 cm x 40 cm x 3
cm
1
25 Relay cw 11 pin socket 10 A 240 Vac 2
26 Time delay relay 10 A 240 Vac 3
27 Triple pole Contactor 20A 240Vac 3
28 Batten type Lamp holder 240Vac 10 A 3
29 Start stop button 240Vac 10A 2
30 Indicating light (Bulb ) 240Vac 25W 3
31 Overload Relay 415V 20A 1
32 Three phase dahlander type
induction motor
5 hp 1
33 Single phase step down
transformer
24024Vac
2500VA
1
79 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
34 Single core PVC insulated
Cable
1mm 2 As required
35 Single core PVC insulated
Cable
25mm 2 As required
36 DIN rail 35 mm As required
37 PVC type Cable tray 50 mm x 50 mm As required
38 Cable ties 4 ldquo As required
39 Flexible wires 075 mm As required
40 PVC Connectors 5 A amp 20 A 240 V As required
41 Terminal block 20A 240Vac As required
Procedures
5 Identify each component according to specification and quantity required from the schematic
diagram attached
6 Test the functionality of each component by using multi-meter or power supply whichever
applicable
7 Wire component according to circuit diagram
8 Three motors operated in sequence by DOL starter operated by manual push button or time
delay relay
a One loop per-cycle
b Continuous operation in a loop
c optional circuit design to represent the same task
d Only one out of three motors to be operated at a time (quiz)
9 Test the functionality of completed project
80 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
BASIC DESIGN INDUSTRIAL MOTOR CONTROL (SEQUENCE CONTROL)
THREE PHASE INDUCTION MOTOR OPERATED IN SEQUENCE BY DIRECT ON LINE
STARTER
LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
81 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
82 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Lcd lamp indicator 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
11 Overload Relay 415V 20A 3
12 Three phase induction motor 5 hp 3
13 Single phase step down transformer 2500VA 1
14 Single core PVC insulated Cable 1mm 2 As required
15 Single core PVC insulated Cable 25mm 2 As required
16 DIN rail 35 mm As required
17 PVC type Cable tray 50 mm x 50 mm As required
18 Cable ties 4 ldquo As required
19 Flexible wires 1 mm Oslash As required
20 PVC Terminal block 10A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the schematic
diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a optional exercise
i Forward Reverse dahlander motor
4 Test the functionality of completed project
83 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
THREE PHASE DAHLANDER TYPE INDUCTION MOTOR OPERATED FORWARD AND
REVERSE OPERATION BY DIRECT ON LINE STARTER
84 ndash 99EASYTECH ENTERPRISE
LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
Introduction
If a motors windings are connected in the star configuration any two phases will be in series across
the supply and hence the line current will be smaller(by 577) than if the windings were connected in
the delta arrangement
Hence larger-type motors with heavy starting currents are first connected in star and then when the
starting currents fall in delta This of course means that all six of the ends of the windings must be
brought to terminations outside the casing (Fig 833)
EZTECH
EZTECH ELECTRICAL INSTALLATION GUIDE
The automatic version of this starter incorporates a timing relay which automatically changes the
connections from star to delta Figs 834 and 835 show the wiring and schematic diagrams for a star
delta starter
Objectives
1 Identify component and the specification
2 Design forward reverse star delta starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
2 ndash 99EASYTECH ENTERPRISE
REV -C
LEGENDMCCB Moulded Case Circuit BreakerTOR Thermal Over Load RelayFOW-C Mains Forward ContactorREV-C Mains Reverse ContactorDC Delta ContactorSC Star ContactorS-SW Mains Selector Switch
SC
V2
W2
U2
DC
V1
W1
U1
TOR
TOR
FOW-C
30A MCCB
TOR
MAIN CIRCUIT FORWARD REVERSE STAR DELTA
RYBN S
-SW
3 PHASEINDUCTION MOTOR
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Relay 10 A 240V 3
5 Triple pole Contactor
6 cw NO NC auxiliary contact
240Vac 20 A 4
7 Overload Relay 415 V 1
8 LED indicator 240vac 5 A 4
9 Start stop button 240Vac 5A 2
10 DIN rail 35 mm As required
11 Flexible wires 1 mm As required
12 Single core PVC insulated
wire
25 mm As required
13 Terminal block 20 A As required
14 Squirrel cage motor 5kW 1
15 5 pin plug and socket 415V 20A 1
16 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
3 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
a Manual star delta
b Manual Forward reverse star delta starter
c Automatic star delta starter
d Automatic Forward reverse star delta starter
4 Test the functionality of completed project
4 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
Objectives
1 Identify component and the specification
2 Design auto transformer starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
5 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Autotransformer starter is used to start a 3 phase induction motor that has a rating between 10 to 15 hp
6 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Autotransformer set 10Kw 415 V 50 Hz 1
5 Triple pole Contactor 240Vac 4
6 Batten type Lamp holder 240 Vac 105 A 4
7 Start stop button 240Vac 10A 4
8 Filament lamp (Bulb ) 240Vac 40W 4
9 DIN rail 35 mm As required
10 Flexible wires 1 mm As required
7 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
11 Single core PVC insulated
wire
25 mm As required
12 Terminal block 20 A As required
13 Squirrel cage motor 10kW 1
14 5 pin plug and socket 415V 20A 1
15 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a open transient autotransformer starter
b close transient autotransformer starter
c Forward reverse autotransformer starter
4 Test the functionality of completed project
8 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
Objectives
1 Identify component and the specification
2 Design rotor resistance starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
9 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Rotor Resistor set 10kW 1
5 Triple pole Contactor 240Vac 20A 4
6 Indicating light 240vac 5 A 4
7 Start stop push button 240Vac 5A 4
8 DIN rail 35 mm As required
9 Flexible wires 1 mm 2 As required
10 Single core PVC insulated wire 25 mm 2 As required
11 Terminal block 20 A As required
12 Slip Ring motor 10kW 1
13 5 pin round 3 phase socket 415V 20A 1
14 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
10 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
4 Test the functionality of completed project
a Dead circuit test b Life circuit test
5 Measure starting and running Amps
LESSON 16
TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
An installation in general will suffer damage
Damage usually occurs on the electric motor control as follows
1 Damage to the main circuit
2 Damage to the control circuit
The cause of the damage
i Overcurrent overload short circuit
ii Leakage current to ground
iii Equipment malfunction
iv The main control circuit
a Trip of main circuit protection devices fire
b Defect of motor terminal such as short circuit fire loose
v The control circuit is not functioning -
a contactor relay relay time overload relay does not work damaged burned
b Loose cable connection disconnected
Detecting and Repairing Damage
Examples of damage are as follows
i Motor does not work
ii Motor function and overload relay trips
iii Motor function but only partially functional control circuit
Methods of detecting damage
Among the known methods necessary to detect damage are as follows
1 Turn off the electricity at the main switch (main switch) in order to avoid any danger during the
work carried out to detect damage
2 Check all the protective gear that controls the motor control main circuit
11 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
3 Make sure the damage function control circuit
4 Check the control circuit according to the schematic circuit diagram of the motor control
5 Check the operation of the control circuit
Note
Use wiring that has been installed on the SYSTEM OF MOTOR CONTROL BOARD by Forward
Reverse control circuit for Star Delta to test and look for damage
SELF-ASSESSMENT QUESTIONS
1 (a) Explain what is meant by the term lsquoback emfrsquo in a motor
(b) Outline the basic differences between series shunt and compound wound dc motors
2 (a) With the aid of diagrams explain how the speed of series shunt and compound-wound motors
may be controlled
(b) A 440V dc shunt-wound motor has a field resistance of 200R and an armature resistance of 06 R
When its speed is 20 rev d second the current drawn from the supply is 122A Calculate its back
emf at this speed If the speed were decreased to 19 revssecond the field flux remaining unchanged
calculate the new back emf and the new armature current
3 A load of 64 kW at 240 V is supplied from the terminals of a shunt-wound dc generator The field
resistance is 180 A Calculate the armature current
4 (a) Explain with the aid of a diagram how a rotating magnetic field may be
(b) What is meant by lsquosynchronous speedrsquo
Calculate the synchronous obtained speed of a 12 pole motor if the supply frequency is 50Hz
5 (a) Explain the action of a synchronous motor
(b) What methods are available to start a synchronous motor Explain with diagrams
6 (a) Explain the action of a cage induction motor
(b) What is meant by the term lsquosliprsquo
Calculate the percentage slip of a six pole induction motor running at 162 revssecond from a 50 Hz
supply
7 Describe with sketches three different ways of starting a single-phase induction motor
12 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
8 Explain with the aid of a sketch the action of a three-phase DOL starter
What are dashpots used for How are remote start and stop buttons connected
9 A I0 kW 240V 50Hz single-phase cage rotor induction motor is 85efficient and has a PF of 068
lagging Calculate the motor current and the value of capacitor required to raise the PF to 093
lagging
10 Calculate the torque developed by an 18 kW four-pole induction motor run at 35 slip from a
50Hz supply
APPENDIX 1
13 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 11
14 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 111
Attachment Reference
httpswwwtlc-directcoukBook621htm
httpwwwstgovmyindexphpms
15 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Direct contact occurs when the worker or consumer receives an electrical shock on touching directly a
live conductor or cable
b Indirect Contact
Here the electric shock occurs due to contact with a part which is connected to the electrical
installation and not to a direct contact with a live cable or conductor possibly due to damages in the
appliance or insulation resulting in leakages of current
Why Electric Shocks Occura Unsafe Work Method or Action Undertaking Electrical Work Without Disconnecting the
Supply
Maintenance or circuit testing work done without disconnecting the supply will have a high possibility
of electrical shocks occurring
bull Not Following Safe Work Procedures
To eliminate the occurrence of electrical shocks each worker has to always follow safe work
procedures which are set by regulations and standards
b Defects in the Electrical System
i Leakage Current
Leakage currents or earth leakage currents can result in the metallic frames becoming live and
energised This can give rise to the danger of electrical shock to the worker consumer or the public if
they hold or come into contact with the metallic frame
ii Exposed Conductor or Disconnected Cable
Exposed conductors or cables which are broken and are alive (energised) can result in electrical shock
when touched The supply source must be immediately isolated or switched off and a report must be
made to the responsible entity
64 First Aid and Basic Pulmonary Resuscitation
i First Aid
First aid is the initial assistance given to a person who has met with an accident is sick or is injured to
prevent the condition of the victim from becoming more serious while awaiting the arrival of the
paramedics (ambulance) or before being brought to the hospital
i Pulmonary Resuscitation
Pulmonary resuscitation has to be undertaken to assist the victim who has breathing difficulties as a
result of being drowned receiving an electrical shock etc Pulmonary resuscitation has to be carried
out in accordance to the correct method as stated in the first aid manuals issued by accredited first aid
bodies
ii First Aid Box
19 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
A first aid box has to be provided by the building owner construction site supervisor or brought
personally by the worker under the supervision of the responsible person
65 Training Programme
The management shall conduct periodic training programmes for the workers with regards to work
safety on aspects including the following -
i Dangers of electrical work being undertaken and how to control those dangers
ii The safety regulations set for the work place and
iii First aid procedures
66 Fire Prevention
Fire Extinguisher A suitable functioning fire extinguisher to control fires has to be made available at
the work place at all times
67 Competent Person
The Electricity Regulations 1994 require that all electrical work has to be undertaken by or under the
direct supervision of a competent person registered with the Energy Commission Besides that the
electrical contractor undertaking the electrical work has also to be registered with the Energy
Commission The installation owner thus has to ensure that the appointed electrical contractor is
registered with the Energy Commission and that the registration is still valid
INSTALLATION CIRCUITS AND SYSTEMS1 Block diagrams
These show using squares rectangles etc the sequence of a system without too much technical detail
eg Figures 1517 and 1526
2 Layout diagrams
These are very similar to block diagrams but they indicate more technical detail and tend to show
items in their correct geographical location (eg Figures 1518 and 1519)
3 Circuitschematic
These show how a circuit functions and takes no account of exact locations of terminals or equipment
(eg Figures 1528 1529 1532 1534 etc)
4 Wiring diagram
These indicate how a circuit or system is physically wired (eg Figures 152 154 156 etc)
Most induction motors are started directly on line but when very large motors are started that way
they cause a disturbance of voltage on the supply lines due to large starting current surges To limit the
starting current surge large induction motors are started at reduced voltage and then have full supply
voltage reconnected when they run up to near rotated speed Two methods are used for reduction of
starting voltage are star delta starting and auto transformer stating
20 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Working Principal of Star-Delta Starter
This is the reduced voltage starting method Voltage reduction during star-delta starting is achieved by
physically reconfiguring the motor windings as illustrated in the figure below During starting the
motor windings are connected in star configuration and this reduces the voltage across each winding 3
This also reduces the torque by a factor of three After a period of time the winding are reconfigured as
delta and the motor runs normally
StarDelta starters are probably the most common reduced voltage starters They are used in
an attempt to reduce the start current applied to the motor during start as a means of reducing the
disturbances and interference on the electrical supply
Traditionally in many supply regions there has been a requirement to fit a reduced voltage
starter on all motors greater than 5HP (4KW) The StarDelta (or WyeDelta) starter is one of the
lowest cost electromechanical reduced voltage starters that can be applied
The StarDelta starter is manufactured from three contactors a timer and a thermal overload
The contactors are smaller than the single contactor used in a Direct on Line starter as they are
controlling winding currents only The currents through the winding are 1root 3 (58) of the
current in the line
There are two contactors that are close during run often referred to as the main contractor and
the delta contactor These are AC3 rated at 58 of the current rating of the motor The third
contactor is the star contactor and that only carries star current while the motor is connected in star
The current in star is one third of the current in delta so this contactor can be AC3 rated at one
third (33) of the motor rating
Star-delta Starter Consists following units
1) Contactors (Main star and delta contactors) 3 Norsquos (For Open State Starter) or 4 Norsquos (Close
Transient Starter)
2) Time relay (pull-in delayed) 1 No
3) Three-pole thermal over current release 1No
4) Fuse elements or automatic cut-outs for the main circuit 3 Nos
5) Fuse element or automatic cut-out for the control circuit 1No
Power Circuit of Star Delta Starter
1 The main circuit breaker serves as the main power supply switch that supplies electricity to the
power circuit
2 The main contactor connects the reference source voltage R Y B to the primary terminal of the
motor U1 V1 W1
21 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
3 In operation the Main Contactor (KM3) and the Star Contactor (KM1) are closed initially and
then after a period of time the star contactor is opened and then the delta contactor (KM2) is
closed The control of the contactors is by the timer (K1T) built into the starter The Star and Delta
are electrically interlocked and preferably mechanically interlocked as well In effect there are
four states
4 The star contactor serves to initially short the secondary terminal of the motor U2 V2 W2 for the
start sequence during the initial run of the motor from standstill This provides one third of DOL
current to the motor thus reducing the high inrush current inherent with large capacity motors at
startup
5 Controlling the interchanging star connection and delta connection of an AC induction motor is
achieved by means of a star delta or wye delta control circuit The control circuit consists of push
button switches auxiliary contacts and a timer
Control Circuit of Star-Delta Starter (Open Transition)
1 The ON push button starts the circuit by initially energizing Star Contactor Coil (KM1) of star
circuit and Timer Coil (KT) circuit
2 When Star Contactor Coil (KM1) energized Star Main and Auxiliary contactor change its
position from NO to NC
3 When Star Auxiliary Contactor (1)( which is placed on Main Contactor coil circuit )became
NO to NC itrsquos complete The Circuit of Main contactor Coil (KM3) so Main Contactor Coil
energized and Main Contactorrsquos Main and Auxiliary Contactor Change its Position from NO
To NC This sequence happens in a friction of time
4 After pushing the ON push button switch the auxiliary contact of the main contactor coil (2)
which is connected in parallel across the ON push button will become NO to NC thereby
providing a latch to hold the main contactor coil activated which eventually maintains the
control circuit active even after releasing the ON push button switch
5 When Star Main Contactor (KM1) close its connect Motor connects on STAR and itrsquos
connected in STAR until Time Delay Auxiliary contact KT (3) become NC to NO
6 Once the time delay is reached its specified Time the timerrsquos auxiliary contacts (KT)(3) in
Star Coil circuit will change its position from NC to NO and at the Same Time Auxiliary
contactor (KT) in Delta Coil Circuit(4) change its Position from NO To NC so Delta coil
energized and Delta Main Contactor becomes NO To NC Now Motor terminal connection
change from star to delta connection
7 A normally close auxiliary contact from both star and delta contactors (5amp6)are also placed
opposite of both star and delta contactor coils these interlock contacts serves as safety
switches to prevent simultaneous activation of both star and delta contactor coils so that one
22 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
cannot be activated without the other deactivated first Thus the delta contactor coil cannot be
active when the star contactor coil is active and similarly the star contactor coil cannot also
be active while the delta contactor coil is active
8 The control circuit above also provides two interrupting contacts to shutdown the motor
The OFF push button switch break the control circuit and the motor when necessary The
thermal overload contact is a protective device which automatically opens the STOP Control
circuit in case when motor overload current is detected by the thermal overload relay this is to
prevent burning of the motor in case of excessive load beyond the rated capacity of the motor
is detected by the thermal overload relay
9 At some point during starting it is necessary to change from a star connected winding to a
delta connected winding Power and control circuits can be arranged to this in one of two
ways ndash open transition or closed transition
What is Open or Closed Transition Starting
(1) Open Transition Starters
Discuss mention above is called open transition switching because there is an open state between
the star state and the delta state
In open transition the power is disconnected from the motor while the winding are reconfigured via
external switching
When a motor is driven by the supply either at full speed or at part speed there is a rotating
magnetic field in the stator This field is rotating at line frequency The flux from the stator field
induces a current in the rotor and this in turn results in a rotor magnetic field
When the motor is disconnected from the supply (open transition) there is a spinning rotor within
the stator and the rotor has a magnetic field Due to the low impedance of the rotor circuit the time
constant is quite long and the action of the spinning rotor field within the stator is that of a
generator which generates voltage at a frequency determined by the speed of the rotor When the
motor is reconnected to the supply it is reclosing onto an unsynchronized generator and this result
in a very high current and torque transient The magnitude of the transient is dependent on the
phase relationship between the generated voltage and the line voltage at the point of closure can
be much higher than DOL current and torque and can result in electrical and mechanical damage
Open transition starting is the easiest to implement in terms or cost and circuitry and if the timing
of the changeover is good this method can work well In practice though it is difficult to set the
necessary timing to operate correctly and disconnectionreconnection of the supply can cause
significant voltagecurrent transients
In Open transition there are Four states
23 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 OFF State All Contactors are open
2 Star State The Main [KM3] and the Star [KM1] contactors are closed and the delta [KM2]
contactor is open The motor is connected in star and will produce one third of DOL torque at one
third of DOL current
3 Open State This type of operation is called open transition switching because there is an
open state between the star state and the delta state The Main contractor is closed and the Delta
and Star contactors are open There is voltage on one end of the motor windings but the other end
is open so no current can flow The motor has a spinning rotor and behaves like a generator
4 Delta State The Main and the Delta contactors are closed The Star contactor is open The
motor is connected to full line voltage and full power and torque are available
(2) Closed Transition StarDelta Starter
There is a technique to reduce the magnitude of the switching transients This requires the use of a
fourth contactor and a set of three resistors The resistors must be sized such that considerable
current is able to flow in the motor windings while they are in circuit
The auxiliary contactor and resistors are connected across the delta contactor In operation just
before the star contactor opens the auxiliary contactor closes resulting in current flow via the
resistors into the star connection Once the star contactor opens current is able to flow round
through the motor windings to the supply via the resistors These resistors are then shorted by the
delta contactor If the resistance of the resistors is too high they will not swamp the voltage
generated by the motor and will serve no purpose
In closed transition the power is maintained to the motor at all time This is achieved by
introducing resistors to take up the current flow during the winding changeover A fourth
contractor is required to place the resistor in circuit before opening the star contactor and then
removing the resistors once the delta contactor is closed These resistors need to be sized to carry
the motor current In addition to requiring more switching devices the control circuit is more
complicated due to the need to carry out resistor switching
In Close transition there are Four states
1 OFF State All Contactors are open
2 Star State The Main [KM3] and the Star [KM1] contactors are closed and the delta [KM2]
contactor is open The motor is connected in star and will produce one third of DOL torque at one
third of DOL current
Star Transition State The motor is connected in star and the resistors are connected across the
delta contactor via the aux [KM4] contactor
24 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Closed Transition State The Main [KM3] contactor is closed and the Delta [KM2] and Star
[KM1] contactors are open Current flows through the motor windings and the transition resistors
via KM4
Delta State The Main and the Delta contactors are closed The transition resistors are shorted out
The Star contactor is open The motor is connected to full line voltage and full power and torque
are available
Effect of Transient in Starter (Open Transient starter)
It is Important the pause between star contactor switch off and Delta contactor switch is on correct
This is because Star contactor must be reliably disconnected before Delta contactor is activated It
is also important that the switch over pause is not too long
For 415v Star Connection voltage is effectively reduced to 58 or 240v The equivalent of 33
that is obtained with Direct Online (DOL) starting
If Star connection has sufficient torque to run up to 75 or 80 of full load speed then the motor
can be connected in Delta mode
When connected to Delta configuration the phase voltage increases by a ratio of V3 or 173 The
phase currents increase by the same ratio The line current increases three times its value in star
connection
During transition period of switchover the motor must be free running with little deceleration
While this is happening ldquoCoastingrdquo it may generate a voltage of its own and on connection to the
supply this voltage can randomly add to or subtract from the applied line voltage This is known as
transient current Only lasting a few milliseconds it causes voltage surges and spikes Known as
a changeover transient
Size of each part of Star-Delta starter
(1) Size of Over Load Relay
For a star-delta starter there is a possibility to place the overload protection in two positions in the
line or in the windings
Overload Relay in Line
In the line is the same as just putting the overload before the motor as with a DOL starter
The rating of Overload (In Line) = FLC of Motor
Disadvantage If the overload is set to FLC then it is not protecting the motor while it is in delta
(setting is x1732 too high)
Overload Relay in Winding
25 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
In the windings means that the overload is placed after the point where the wiring to the contactors
are split into main and delta The overload then always measures the current inside the windings
The setting of Overload Relay (In Winding) =058 X FLC (line current)
Disadvantage We must use separate short circuit and overload protections
(2) Size of Main and Delta Contractor
1 There are two contactors that are close during run often referred to as the main contractor and
the delta contactor These are AC3 rated at 58 of the current rating of the motor
Size of Main Contactor= IFL x 058
(3) Size of Star Contractor
The third contactor is the star contactor and that only carries star current while the motor is
connected in star The current in star is 1 radic3= (58) of the current in delta so this contactor can
be AC3 rated at one third (33) of the motor rating
Size of Star Contactor= IFL x 033
Motor Starting Characteristics of Star-Delta Starter
Available starting current 33 Full Load Current
Peak starting current 13 to 26 Full Load Current
Peak starting torque 33 Full Load Torque
Advantages of Star-Delta starter
The operation of the star-delta method is simple and rugged
It is relatively cheap compared to other reduced voltage methods
Good TorqueCurrent Performance
It draws 2 times starting current of the full load ampere of the motor connected
Disadvantages of Star-Delta starter
Low Starting Torque (Torque = (Square of Voltage) is also reduce)
Break In Supply ndash Possible Transients
Six Terminal Motor Required (Delta Connected)
It requires 2 set of cables from starter to motor
It provides only 33 starting torque and if the load connected to the subject motor requires higher
starting torque at the time of starting than very heavy transients and stresses are produced while
changing from star to delta connections and because of these transients and stresses many
electrical and mechanical break-down occurs
26 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
In this method of starting initially motor is connected in star and then after change over the motor
is connected in delta The delta of motor is formed in starter and not on motor terminals
High transmission and current peaks When starting up pumps and fans for example the load
torque is low at the beginning of the start and increases with the square of the speed When
reaching approx 80-85 of the motor rated speed the load torque is equal to the motor torque and
the acceleration ceases To reach the rated speed a switch over to delta position is necessary and
this will very often result in high transmission and current peaks In some cases the current peak
can reach a value that is even bigger than for a DOL start
Applications with a load torque higher than 50 of the motor rated torque will not be able to start
using the start-delta starter
Low Starting Torque The star-delta (wye-delta) starting method controls whether the lead
connections from the motor are configured in a star or delta electrical connection The initial
connection should be in the star pattern that results in a reduction of the line voltage by a factor of
1radic3 (577) to the motor and the current is reduced to 13 of the current at full voltage but the
starting torque is also reduced 13 to 15 of the DOL starting torque
The transition from star to delta transition usually occurs once nominal speed is reached but is
sometimes performed as low as 50 of nominal speed which make transient Sparks
Features of star-delta starting
1 For low- to high-power three-phase motors
2 Reduced starting current
3 Six connection cables
4 Reduced starting torque
5 Current peak on changeover from star to delta
6 Mechanical load on changeover from star to delta
Application of Star-Delta Starter
The star-delta method is usually only applied to low to medium voltage and light starting
Torque motors
The received starting current is about 30 of the starting current during direct on line start and the
starting torque is reduced to about 25 of the torque available at a DOL start This starting
method only works when the application is light loaded during the start If the motor is too heavily
27 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
loaded there will not be enough torque to accelerate the motor up to speed before switching over
to the delta position
LESSON 1 WIRING SYSTEM OF SINGLE PHASE DISTRIBUTION BOARD
Introduction
28 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
29 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
30 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
31 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 2 WIRING SYSTEM OF SINGLE PHASE LIGHTING CIRCUIT Introduction
Objectives
1 Identify component and the specification
2 Wire component according to the schematic diagram
3 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Wiring bay Perforated metal 180 cm x 180 cm 1
2 Cut out fuse 63 A 240 V 1
3 Neutral link 1
4 Single pole one way switch cw
switch box
5A 240Vac 4
5 single pole two way switch cw
switch box
5A 240Vac 2
6 RCCB In = 40 A Tripping current
100mA240 Vac 50 Hz
1
7 Main switch 32 A 240V 1
8 kWatthour meter 40 A 240 Vac 1
9 Single pole MCB 6A 240 Vac 1
10 Self tapping Wood screw As required
11 DIN rail 35 mm width As required
32 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
12 PVC trunking 50 mm x 50 mm As required
13 Terminal blocks 5 A As required
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
1 One way switch to control one lamp
2 One way switch to control two lamps
3 Two of two way switch to control one lamp
4 Two of single pole two way switch and one of an intermediate switch to control one
lamp
5 One unit of ceiling fan and fan regulator to be controlled by one way switch
4 Test the functionality of completed project
LESSON 3ndash WIRING SYSTEM OF SINGLE PHASE POWER CIRCUIT Introduction
33 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
34 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify types of component and its specification
2 Wire component according to the schematic diagram given
3 Test the functionality of the circuit dead circuit test life circuit test
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board Perforated Metal 1
2 kWh meter 240 V 40 A 1
3 Socket outlet 13A 240Vac 4
4 RCCB 40A Trip Amps
30mA240 Vac
1
5 3 pin socket 240Vac 13A 4
6 Single pole MCB 20A 240 V 2
7 DOL starter 1 kW 240Vac 2
8 1 phase induction motor 2Hp 240 Vac 1
9 Cooker control unit 4kW 240Vac 1
10 Water heater point 4kW 240 Vac 1
11 DIN rail 35 mm As required
12 PVC casing 20mm As required
13 Flexible wires 05 mm As required
14 Terminal block 10 A As required
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Wire two unit of 13 A socket outlet in radial circuit
3 Wire four units of 13 A socket outlet in ring circuit
4 Wire one unit DOL starter for air-conditioner point
5 Wire one unit of cooker control unit point
6 Wire one unit of water heater point
7 Test the functionality of each component by using mmeter or power supply whichever
applicable
8 Wire component according to circuit diagram
9 Test the functionality of completed project dead circuit test life circuit test
Note
35 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Ensure that the correct rating of protection device and size of wire used
LESSON 4ndash CONDUIT BENDING AND TRUNKING FABRICATION TECHNIQUE
Common fitting used in an industrial wiring
Cutting and threading the condute
36 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
37 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
38 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify conduit fitting and the specification
2 Measure and Cut steel conduit according to specified dimension
3 Bend and fabricate conduit at 45 90 according to layout diagram
4 Wire component according to the schematic diagram
5 Test the functionality of the circuit
39 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Conduit Bender Oslash 19 mm ( frac34 ldquo) 1
2 Measuring Tape 3 metre 1
3 Hacksaw frame and blade 30cm 1
4 Conduit cutter 1
5 Pipe Vise 1
6 Pipe Wrench 1
7 Ratchet Dies 20 mm 1
8 Metal trunking 50 mm x 50 mm 1
9 GI conduit 20mm 1
10 End box 20 mm 1
11 Flexible wires 05 mm As required
12 Connectors 5 A As required
13 Single core PVC ins Cable 25 mm 2 As required
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Wire two unit of 13 A socket outlet in radial circuit
3 Wire four unit of 13 A socket outlet in ring circuit
4 Wire one unit DOL starter for air-conditioner point
5 Wire one unit of cooker control unit point
6 Wire one unit of water heater point
7 Test the functionality of each component by using multimeter or power supply whichever
applicable
8 Wire component according to circuit diagram
9 Test the functionality of completed project
Note
Ensure that the rating of protection device and size of wire
K prior to 31 March
2004 (BS 7671)
(formerly)
bare conductor
sleeved at terminations (formerly)
40 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 5 ndashWIRING SYSTEM OF 1 Oslash LIGHTING AND POWER CIRCUIT
POWER CIRCUITSa Radial circuits
Radial circuits are arranged in the same way as item 1 above in lighting layouts in that each socket
outlet is supplied via the previous one
Points to note
1 The number of socket outlets complying with BS 1363 is unlimited for a floor area of up to 50m 2 if
the circuit protection is a 30 A or 32 A cartridge fuse or circuit breaker the cable being 4 mm PVC
copper or 25 mm2 mineral insulated (mi)
2 The number of socket outlets is unlimited for a floor area up to 20 m 2 with any type of circuit
protection of 20 A using 25 mm2 PVC copper cable or 15 mm2 mi
3 The total number of fused spurs is unlimited
b ring final circuits
These circuits are the same as radial circuits except that the final socket outlet is wired back to the
supply position In effect any outlet is supplied from two directions (Fig 152)
Points to note
1 Every twin-socket outlet counts as two single-socket outlets
2 The number of non-fused spurs must not exceed the total number of points on the ring Fig 158
shows seven points on the ring and five spurs
3 The fuse rating of a fused spur box must not exceed 13 A and the current rating of all points supplied
by the fused spur must not exceed 13 A
4 Non-fused spurs must supply no more than one single or one double socket on the ring Fig 158
shows seven points on the ring and five spurs rating of all points supplied by the fused spur must not
exceed 13 A or one stationary appliance
CapacityMain conductor size
copper (mm2)
Earth conductor
size (mm2)
Circuit breaker
capacity (A)
Up to 600 W 15 15 6
600ndash1200 W 1525 15 10
1200ndash1800 W 254 25 16
41 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Ring circuit
(floor area 100 m2)25 15 3032
A2 radial circuit
(floor area 75 m2)40 25 3032
A3 radial circuit
(floor area 50 m2)25 15 20
Air conditioner (15 tonne) 60 60 3032
Cooker 60 60 3032
Water heater 40 40 20
Objectives
1 Identify component and the specification
2 Wire component according to the schematic diagram
3 Test the functionality of the circuit
42 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board Perforated 1
2 Cut out fuse and neutral link 60A 240V 1each
3 kWh meter 240V 40A 1
4 Switched Socket outlet 13A 240Vac 4
5 Single pole two way switch cw switch
box
5A 240Vac 2
6 RCCB ELCB 63 A Tripping current 100mA
415 Vac
1
7 3 pin plug 240Vac 13A 4
8 Single pole MCB 20 A 2
9 Single pole MCB 6A 1
10 Single pole MCB 20A 2
11 DOL starter 240Vac 2
12 1 phase induction motor 2hp 240 Vac 1
13 Self tapping Wood screw As required
14 DIN rail Stainless steel allum35 mm As required
15 PVC pipe 20mm dia As required
16 End box 20 mm dia 4
17 Flexible wires 05 mm 2 As required
18 Connectors 5 A As required
Procedures
43 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
4 Test the functionality of completed project
LESSON 6 ndash WIRING SYSTEM OF 3 Oslash DISTRIBUTION BOARD
Introduction
44 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
45 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
46 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
47 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
48 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify each component and the specification
2 Wire component according to the schematic diagram given
3 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting Board 450 x 600 mm Perforated metal 1
2 5 pin round socket and plug 415V ac 32A 1
3 Cut out fuse 60 A 3
4 Neutral link 1
5 kWatt hour meter 415V 60A 1
6 ELCB RCCB 3P+N In=63A415 Vac I trip= 300mA 1
7 ELCB RCCB 3P+N In=63A415 Vac I trip= 30mA 1
8 Single pole MCB 6A 240 V 3
9 Single pole MCB 20A 240 V 3
10 DOL starter 20 A 240Vac 2
11 Socket outlet 15 A 240 Vac 1
12 Switched Socket outlet 13 A 240 Vac 3
13 Led indicating light 5A 240 Vac 3
14 Single pole 4 gang 1 way switch 5A 240 Vac 2
15 Single pole 2 way switch 5A 240 Vac 2
16 1 phase induction motor 1 kW 240Vac 1
17 Metal trunking 30 mm x30 mm As required
18 Self tapping Wood screw 4 mm x 20 mm As required
19 DIN rail 25 mm x 1mm
20 GI steel rigid conduit 20mm As required
21 Flexible conduit 20mm As required
22 End box 20 mm 4
23 Flexible wires 05 mm 2 As required
24 Single core PVC insulated wire 15 mm 2 As required
25 Single core PVC insulated wires 25 mm 2 As required
26 Terminal block 10 A As required
Procedures
49 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify each components and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
4 Test the functionality of completed project
1 dead circuit test
2 life circuit
Note Proper earthing should be made
50 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 7 ndash WIRING SYSTEM OF THREE PHASE LIGHTING AND POWER CIRCUIT
51 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
52 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify component and the specification
2 Wire component according to the schematic diagram
3 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting bay Board Perforated metal 180 cm x 180 cm 1
2 k Watt hour meter 415V 60A 1
3 MCCB 415V 60A
4 ELCB RCCB In=60A415 Vac I trip=30mA 1
5 5 pin round Socket and
plug
415Vac 32A 4
6 Single pole MCB 6A 1
7 Triple pole MCB 20A 2
8 Triple pole Main switch 60A 1
9 DOL starter 240Vac 2
10 3 phase induction motor 2hp 415 Vac 1
11 1 phase induction motor 1
12 Metal trunking 30 mm x30 mm As required
13 Self tapping Wood screw 4 mm x 20 mm As required
14 DIN rail 25 mm x 1mm
15 GI steel rigid conduit 20mm As required
16 Flexible conduit 20mm As required
17 End box 20 mm 4
18 Flexible wires 05 mm As required
19 Connectors 10 A As required
Procedures
1 Identify each components and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
4 Test the functionality of completed project
1 dead circuit 2 life circuit test
5 Record the current drawn by the load as connected in star and delta
Note Proper earthing should be made
53 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 8 INSPECTION AND TESTING OF ELECTRICAL INSTALLATION
On completion of a wiring installation a number of tests on the installation have to be conducted to
ascertain that the wiring circuits and connected appliances are safe for use Prior to carrying out the
tests an inspection has to be done The results of the inspectionsupervision and test have to be
presented in Form G (as in Appendix IV) and Form H (as in Appendix V)
To have the test certification as in Form H the following tests shall be conducted
i Continuity Test
ii Insulation Resistance Test
iii Polarity Test
iv Earth Electrode Resistance test and
v Residual Current Device Test
1 Continuity Test
There are 3 main types of continuity tests for the final circuits-
i Protection Conductor Continuity Test
ii Final Ring Circuit Conductor Continuity Test
iii Live and Neutral Conductor Continuity Test
a) Protection Conductor Continuity Test
bull To ascertain that all protection conductors are connected in the correct and effective manner
bull Test equipment ndash Multimeter (Ohm range) or Ohm meter
54 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
bull Test Method
1 1048766 Ensure that the main switch RCD and MCB are open circuited (switched off) and all loads
are disconnected
2 1048766 Connected the test leads as in the Figure 81 The meter reading shall be less than 1 Ω
55 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Final Ring Circuit Conductor Continuity Test
bull To ensure that all conductors around the ring circuit have continuity
bull Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
bull Test Method
1 1048766 Disconnect both the supply source live conductors from the MCB the neutral conductor
from the neutral terminals and the earth conductor from the earth terminal in the distribution
fuse box
2 1048766 Connect the test leads as in the Figure 82 (EE)
3 1048766 Repeat the procedure for (L-L) and (N-N)
4 1048766 The meter reading value shall be less than 1 ohm
56 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Live and Neutral Conductor Continuity Test
a To ensure that each conductor in the circuit has continuity
b Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
2 Test Method
1 1048766 Switch off the Main switch RCD and MCB
2 1048766 Disconnect all loads
3 1048766 Switch on all switches in the circuit
4 1048766 Disconnect the fusesfinal circuit breakers and close the circuit
5 1048766 Carry out the test as shown in Figure 83
6 1048766 The meter reading value shall be less than 1Ω
57 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
58 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
CONTINUITY TEST
Insulation Resistance Test
i Ensure that there is no leakage current between phase conductors phase and neutral conductors and
phase conductor and earth
ii Test the strength of the cable insulation
iii Test Equipment ndash Insulation Resistance Tester operating voltage is 250VDC or 500VDC
iv Test Method
1 1048766 Switch off main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
59 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
4 1048766 Carry out test as in the Table below
5 1048766 Meter reading value shall be less than 1 Megaohm
60 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
61 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Insulation resitance test
62 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
INSULATION RESISTANCE TEST BETWEEN CONDUCTORS AND OPPOSITE POLARITY
Polarity Testi Ensure that each fuse or single pole control and protection device is connected only in the phase
conductor
ii Intermediate contact of Edison screw lamp holder is connected to the phase conductor
iii Ensure that phase neutral and earth conductors at socket outlets are connected at the correct
terminals
iv Test Equipment ndash Multimeter (Ohm range) or Ohm meter
v Test Method
1 1048766 Switch off Main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in Figure 85
63 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
5 1048766 Test switches and single phase control devices at the phase conductors
6 1048766 Test socket outlet connection sources
7 1048766 Test Edison screw lamp holder connections
8 1048766 Meter reading value shall be less than 1 Ω
64 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Polarity test
65 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Earth Electrode Resistance Testi To test the earth electrode resistance
ii To ascertain the suitability of the location of the electrode
iii To ensure that the electrode is not buried within the resistance area of another electrode
iv Test equipment ndash Earth Resistance Tester
v Test method -
1 1048766 Terminal rsquoErsquo is connected to the electrode to be tested (green conductor)
2 1048766 Terminal lsquoPrsquo is connected to the potential spike (yellow conductor) at a distance of 10
meters from the earth electrode
3 1048766 Terminal lsquoCrsquo is connected to the current spike (red conductor) at a distance of 20 meters
from the earth electrode
Earth Electrode Resistance Measurement Method (Figure 86)
This test must be repeated at least three times to ensure that the reading is not affected by interacting
earthing regions
i Record the first reading (Z1) Example Z1 = 10 Ω
ii Move the voltage spike to a distance of 6 meters from the original position Record the second
reading (Z2 ) Example Z2 = 10 Ω
iii Move the voltage spike to a distance of 6 meters from the original position Record the third
reading (Z3) Example Z3 = 10 Ω
66 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Residual Current Device Testi Ensure that the residual current device (RCD) trips within the set time on the occurrence of current
leakage to earth
ii Test Equipment ndash RCD Tester RCCB Tester
iii Test Method 1
1 1048766 Use the Trip Test Button
2 1048766 Press the trip button found on the RCD to determine if it trips or otherwise This test would
not be able to determine the sensitivity of the RCD nor the time taken for it to trip
iv Test Method 2
i 1048766 Use a RCD Tester
ii This equipment is equipped with a 13A plug which can be connected to a 13A socket outlet
Select the RCD sensitivity to be the same as the sensitivity of the RCD to be tested to
determine if the RCD can trip The time to trip shall not exceed 40 mS
iii 1048766 Test method ndash
a) Position the selection switch in accordance with the sensitivity of the RCD used
Example 100 mA 01 A
b) Position the operations switch to lsquoNo Triprsquo (frac12 Rated mA = 50) connect the 3 pin plug to
the 13A socket outlet
67 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
c) Switch on the 13A socket outlet ndash ensure that the P-N and P-E lights light up
This shows that the polarity is correct (Note if both the lights as above do not light up the test cannot
be continued)
d) Press the test button ndash the reading shows less than 200 mS and simultaneously the lsquotestrsquo light lights
up and the P-N and P-E lights do not light up At that instant the RCD will not trip
e) Move the selection switch to 180o (+ve wave) ndash repeat steps (d) and (e) Move the operations
switch to lsquoTriprsquo (Rated mA = 100)
g) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200mS
h) Move the selection switch to 0o (-ve wave)
i) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
j) The above test is repeated until a near correct reading is obtained
k) Record the test results
l) Change the operations switch to lsquoFast Triprsquo and press the test button ndash RCD will trip within a
time not exceeding 40 millisecond
m) Repeat a number of times at 0o or 180o
On completion of a wiring installation a number of tests on the installation have to be conducted to
ascertain that the wiring circuits and connected appliances are safe for use Prior to carrying out the
tests an inspection has to be done the following tests shall be conducted
i Continuity Test
ii Insulation Resistance Test
iii Polarity Test
iv Earth Electrode Resistance test and
v Residual Current Device Test
821 Continuity Test
There are 3 main types of continuity tests for the final circuits-
i Protection Conductor Continuity Test
ii Final Ring Circuit Conductor Continuity Test
68 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
iii Live and Neutral Conductor Continuity Test
a) Protection Conductor Continuity Test
bull To ascertain that all protection conductors are connected in the correct and effective manner
bull Test equipment ndash Multimeter (Ohm range) or Ohm meter
bull Test Method
1 1048766 Ensure that the main switch RCD and MCB are open circuited (switched off) and all loads are
disconnected
2 1048766 Connected the test leads as in the Figure 81
3 1048766 The meter reading shall be less than 1 Ω
Final Ring Circuit Conductor Continuity Test
bull To ensure that all conductors around the ring circuit have continuity
bull Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
bull Test Method
1 1048766 Disconnect both the supply source live conductors from the MCB the neutral conductor
from the neutral terminals and the earth conductor from the earth terminal in the distribution
fuse box
2 1048766 Connect the test leads as in the Figure 82 (EE)
3 1048766 Repeat the procedure for (L-L) and (N-N)
4 1048766 The meter reading value shall be less than 1 ohm Figure 82 - Final Ring Circuit Conductor
Continuity Test Ohm Meter
Disconnect both the supply source cables from mcbfuse
Take readings at earth conductors of both sources and note resistance readings
Live and Neutral Conductor Continuity Test
1 To ensure that each conductor in the circuit has continuity
2 Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
3 Test Method
1 1048766 Switch off the Main switch RCD and MCB
2 1048766 Disconnect all loads
3 1048766 Switch on all switches in the circuit
4 1048766 Disconnect the fusesfinal circuit breakers and close the circuit
5 1048766 Carry out the test as shown in Figure 83
6 1048766 The meter reading value shall be less than 1 ohm Figure 83 - Live and Neutral
Conductor Continuity Test Ohm Meter
Insulation Resistance Test
69 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
i Ensure that there is no leakage current between phase conductors phase and neutral conductors and
phase conductor and earth
ii Test the strength of the cable insulation
iii Test Equipment ndash Insulation Resistance Tester Operating voltage is 250VDC or 500VDC
iv Test Method
1 1048766 Switch off main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in the Table below
5 1048766 Meter reading value shall be less than 1 Megaohm
Polarity Test
i Ensure that each fuse or single pole control and protection device is connected only in the phase
conductor
ii Intermediate contact of Edison screw lamp holder is connected to the phase conductor
iii Ensure that phase neutral and earth conductors at socket outlets are connected at the correct
terminals
iv Test Equipment ndash Multimeter (Ohm range) or Ohm meter
v Test Method
1 1048766 Switch off Main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in Figure 85
5 1048766 Test switches and single phase control devices at the phase conductors
6 1048766 Test socket outlet connection sources
7 1048766 Test Edison screw lamp holder connections
8 1048766 Meter reading value shall be less than 1 Ω
Earth Electrode Resistance Test
i To test the earth electrode resistance
70 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
ii To ascertain the suitability of the location of the electrode
iii To ensure that the electrode is not buried within the resistance area of another electrode
iv Test equipment ndash Earth Resistance Tester
v Test method -
1 1048766 Terminal rsquoErsquo is connected to the electrode to be tested (green conductor)
2 1048766 Terminal lsquoPrsquo is connected to the potential spike (yellow conductor) at a distance of 10
meters from the earth electrode
3 1048766 Terminal lsquoCrsquo is connected to the current spike (red conductor) at a distance of 20 meters
from the earth electrode E P C Electrode 10 meter 10 meter
Figure 86 ndash Earth Electrode Resistance Measurement Test Equipment
Earth Electrode Resistance Measurement Method (Figure 86)
This test must be repeated at least three times to ensure that the reading is not affected by interacting
earthing regions
i Record the first reading (Z1) Example Z1 = 10 Ω
ii Move the voltage spike to a distance of 6 meters from the original position Record the second
reading (Z2) Example Z2 = 10 Ω
iii Move the voltage spike to a distance of 6 meters from the original position Record the third
reading (Z3)
Example Z3 = 10 Ω
Residual Current Device Test
71 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
i Ensure that the residual current device (RCD) trips within the set time on the occurrence of current
leakage to earth
ii Test Equipment ndash RCD Tester RCCB Tester
iii Test Method 1
1 1048766 Use the Trip Test Button
2 1048766 Press the trip button found on the RCD to determine if it trips or otherwise This test would
not be able to determine the sensitivity of the RCD nor the time taken for it to trip
iv Test Method 2
1048766 Use a RCD Tester
This equipment is equipped with a 13A plug which can be connected to a 13A socket outlet Select the
RCD sensitivity to be the same as the sensitivity of the RCD to be tested to determine if the RCD can
trip The time to trip shall not exceed 40 mS
1048766 Test method ndash
a) Position the selection switch in accordance with the sensitivity of the RCD used
Example 100 mA 01 A
b) Position the operations switch to lsquoNo Triprsquo (frac12 Rated mA = 50) connect the 3 pin plug to
the 13A socket outlet
c) Switch on the 13A socket outlet ndash ensure that the P-N and P-E lights light up This shows that
the polarity is correct (Note if both the lights as above do not light up the test cannot be
continued)
d) Press the test button ndash the reading shows less than 200 millisecond and simultaneously the
lsquotestrsquo light lights up and the P-N and P-E lights do not light up At that instant the RCD will
not trip
e) Move the selection switch to 180o (+ve wave) ndash repeat steps (d) and (e) = 100)
f) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
g) Move the selection switch to 0o (-ve wave)
h) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
i) The above test is repeated until a near correct reading is obtained
j) Record the test results
k) Change the operations switch to lsquoFast Triprsquo and press the test button ndash RCD will trip within a
time not exceeding 40 mS
l) Repeat a number of times at 0o or 180o
72 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 9 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (DC)
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
73 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Start stop button 240Vac 5A 2
9 Filament lamp (Bulb ) 240Vac 40W 3
10 Overload Relay 415V 20A 3
11 Three phase induction motor 5 hp 3
12 Single phase step down transformer 2500VA 1
13 Single core PVC insulated Cable 1mm 2 As required
14 Single core PVC insulated Cable 25mm 2 As required
15 DIN rail 35 mm As required
16 PVC type Cable tray 50 mm x 50 mm As required
17 Cable ties 4 ldquo As required
18 Flexible wires 05 mm As required
19 PVC Connectors 5 A amp 20 A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the schematic
diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a optional exercise
i Simple DOL starter
ii Forward reverse DOL starter
iii Forward Reverse Dahlander motor
iv Three motors operated in sequence by DOL starter operated by manual push
button or time delay relay
74 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
a One loop per-cycle
b Continuous operation in a loop
c optional circuit design to represent the same task
v Only one out of three motors to be operated at a time (quiz)
4 Test the functionality of completed project
LESSON 10 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (AC)
75 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 1
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Lamp point 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
76 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
11 Overload Relay 415V 20A 3
12 Three phase induction
motor
5 hp 3
13 Single core PVC insulated
Cable
1mm 2 As required
14 Single core PVC insulated
Cable
25mm 2 As required
15 DIN rail 35 mm As required
16 PVC type Cable tray 50 mm x 50 mm As required
17 Cable ties 4 ldquo As required
18 Flexible wires 05 mm As required
19 PVC Connectors 5 A amp 20 A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the
schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram optional exercise
4 Simple DOL starter
5 Forward reverse DOL starter
6 Test the functionality of completed project
77 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 1
78 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
cm
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Indicating light 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
11 Overload Relay 415V 20A 3
12 Three phase induction motor 5 hp 3
13 Single phase step down
transformer
2500VA 1
14 Single core PVC insulated
Cable
1mm 2 As required
15 Single core PVC insulated
Cable
25mm 2 As required
16 DIN rail 35 mm As required
17 PVC type Cable tray 50 mm x 50 mm As required
18 Cable ties 4 ldquo As required
19 Flexible wires 05 mm As required
20 PVC Connectors 5 A amp 20 A 240 V As required
21 Single pole MCB 6A 240 V 1
22 Single pole MCB 2A 240 V 1
23 Triple pole MCB 20A 415 V 1
24 Mounting board 30 cm x 40 cm x 3
cm
1
25 Relay cw 11 pin socket 10 A 240 Vac 2
26 Time delay relay 10 A 240 Vac 3
27 Triple pole Contactor 20A 240Vac 3
28 Batten type Lamp holder 240Vac 10 A 3
29 Start stop button 240Vac 10A 2
30 Indicating light (Bulb ) 240Vac 25W 3
31 Overload Relay 415V 20A 1
32 Three phase dahlander type
induction motor
5 hp 1
33 Single phase step down
transformer
24024Vac
2500VA
1
79 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
34 Single core PVC insulated
Cable
1mm 2 As required
35 Single core PVC insulated
Cable
25mm 2 As required
36 DIN rail 35 mm As required
37 PVC type Cable tray 50 mm x 50 mm As required
38 Cable ties 4 ldquo As required
39 Flexible wires 075 mm As required
40 PVC Connectors 5 A amp 20 A 240 V As required
41 Terminal block 20A 240Vac As required
Procedures
5 Identify each component according to specification and quantity required from the schematic
diagram attached
6 Test the functionality of each component by using multi-meter or power supply whichever
applicable
7 Wire component according to circuit diagram
8 Three motors operated in sequence by DOL starter operated by manual push button or time
delay relay
a One loop per-cycle
b Continuous operation in a loop
c optional circuit design to represent the same task
d Only one out of three motors to be operated at a time (quiz)
9 Test the functionality of completed project
80 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
BASIC DESIGN INDUSTRIAL MOTOR CONTROL (SEQUENCE CONTROL)
THREE PHASE INDUCTION MOTOR OPERATED IN SEQUENCE BY DIRECT ON LINE
STARTER
LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
81 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
82 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Lcd lamp indicator 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
11 Overload Relay 415V 20A 3
12 Three phase induction motor 5 hp 3
13 Single phase step down transformer 2500VA 1
14 Single core PVC insulated Cable 1mm 2 As required
15 Single core PVC insulated Cable 25mm 2 As required
16 DIN rail 35 mm As required
17 PVC type Cable tray 50 mm x 50 mm As required
18 Cable ties 4 ldquo As required
19 Flexible wires 1 mm Oslash As required
20 PVC Terminal block 10A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the schematic
diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a optional exercise
i Forward Reverse dahlander motor
4 Test the functionality of completed project
83 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
THREE PHASE DAHLANDER TYPE INDUCTION MOTOR OPERATED FORWARD AND
REVERSE OPERATION BY DIRECT ON LINE STARTER
84 ndash 99EASYTECH ENTERPRISE
LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
Introduction
If a motors windings are connected in the star configuration any two phases will be in series across
the supply and hence the line current will be smaller(by 577) than if the windings were connected in
the delta arrangement
Hence larger-type motors with heavy starting currents are first connected in star and then when the
starting currents fall in delta This of course means that all six of the ends of the windings must be
brought to terminations outside the casing (Fig 833)
EZTECH
EZTECH ELECTRICAL INSTALLATION GUIDE
The automatic version of this starter incorporates a timing relay which automatically changes the
connections from star to delta Figs 834 and 835 show the wiring and schematic diagrams for a star
delta starter
Objectives
1 Identify component and the specification
2 Design forward reverse star delta starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
2 ndash 99EASYTECH ENTERPRISE
REV -C
LEGENDMCCB Moulded Case Circuit BreakerTOR Thermal Over Load RelayFOW-C Mains Forward ContactorREV-C Mains Reverse ContactorDC Delta ContactorSC Star ContactorS-SW Mains Selector Switch
SC
V2
W2
U2
DC
V1
W1
U1
TOR
TOR
FOW-C
30A MCCB
TOR
MAIN CIRCUIT FORWARD REVERSE STAR DELTA
RYBN S
-SW
3 PHASEINDUCTION MOTOR
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Relay 10 A 240V 3
5 Triple pole Contactor
6 cw NO NC auxiliary contact
240Vac 20 A 4
7 Overload Relay 415 V 1
8 LED indicator 240vac 5 A 4
9 Start stop button 240Vac 5A 2
10 DIN rail 35 mm As required
11 Flexible wires 1 mm As required
12 Single core PVC insulated
wire
25 mm As required
13 Terminal block 20 A As required
14 Squirrel cage motor 5kW 1
15 5 pin plug and socket 415V 20A 1
16 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
3 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
a Manual star delta
b Manual Forward reverse star delta starter
c Automatic star delta starter
d Automatic Forward reverse star delta starter
4 Test the functionality of completed project
4 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
Objectives
1 Identify component and the specification
2 Design auto transformer starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
5 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Autotransformer starter is used to start a 3 phase induction motor that has a rating between 10 to 15 hp
6 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Autotransformer set 10Kw 415 V 50 Hz 1
5 Triple pole Contactor 240Vac 4
6 Batten type Lamp holder 240 Vac 105 A 4
7 Start stop button 240Vac 10A 4
8 Filament lamp (Bulb ) 240Vac 40W 4
9 DIN rail 35 mm As required
10 Flexible wires 1 mm As required
7 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
11 Single core PVC insulated
wire
25 mm As required
12 Terminal block 20 A As required
13 Squirrel cage motor 10kW 1
14 5 pin plug and socket 415V 20A 1
15 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a open transient autotransformer starter
b close transient autotransformer starter
c Forward reverse autotransformer starter
4 Test the functionality of completed project
8 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
Objectives
1 Identify component and the specification
2 Design rotor resistance starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
9 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Rotor Resistor set 10kW 1
5 Triple pole Contactor 240Vac 20A 4
6 Indicating light 240vac 5 A 4
7 Start stop push button 240Vac 5A 4
8 DIN rail 35 mm As required
9 Flexible wires 1 mm 2 As required
10 Single core PVC insulated wire 25 mm 2 As required
11 Terminal block 20 A As required
12 Slip Ring motor 10kW 1
13 5 pin round 3 phase socket 415V 20A 1
14 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
10 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
4 Test the functionality of completed project
a Dead circuit test b Life circuit test
5 Measure starting and running Amps
LESSON 16
TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
An installation in general will suffer damage
Damage usually occurs on the electric motor control as follows
1 Damage to the main circuit
2 Damage to the control circuit
The cause of the damage
i Overcurrent overload short circuit
ii Leakage current to ground
iii Equipment malfunction
iv The main control circuit
a Trip of main circuit protection devices fire
b Defect of motor terminal such as short circuit fire loose
v The control circuit is not functioning -
a contactor relay relay time overload relay does not work damaged burned
b Loose cable connection disconnected
Detecting and Repairing Damage
Examples of damage are as follows
i Motor does not work
ii Motor function and overload relay trips
iii Motor function but only partially functional control circuit
Methods of detecting damage
Among the known methods necessary to detect damage are as follows
1 Turn off the electricity at the main switch (main switch) in order to avoid any danger during the
work carried out to detect damage
2 Check all the protective gear that controls the motor control main circuit
11 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
3 Make sure the damage function control circuit
4 Check the control circuit according to the schematic circuit diagram of the motor control
5 Check the operation of the control circuit
Note
Use wiring that has been installed on the SYSTEM OF MOTOR CONTROL BOARD by Forward
Reverse control circuit for Star Delta to test and look for damage
SELF-ASSESSMENT QUESTIONS
1 (a) Explain what is meant by the term lsquoback emfrsquo in a motor
(b) Outline the basic differences between series shunt and compound wound dc motors
2 (a) With the aid of diagrams explain how the speed of series shunt and compound-wound motors
may be controlled
(b) A 440V dc shunt-wound motor has a field resistance of 200R and an armature resistance of 06 R
When its speed is 20 rev d second the current drawn from the supply is 122A Calculate its back
emf at this speed If the speed were decreased to 19 revssecond the field flux remaining unchanged
calculate the new back emf and the new armature current
3 A load of 64 kW at 240 V is supplied from the terminals of a shunt-wound dc generator The field
resistance is 180 A Calculate the armature current
4 (a) Explain with the aid of a diagram how a rotating magnetic field may be
(b) What is meant by lsquosynchronous speedrsquo
Calculate the synchronous obtained speed of a 12 pole motor if the supply frequency is 50Hz
5 (a) Explain the action of a synchronous motor
(b) What methods are available to start a synchronous motor Explain with diagrams
6 (a) Explain the action of a cage induction motor
(b) What is meant by the term lsquosliprsquo
Calculate the percentage slip of a six pole induction motor running at 162 revssecond from a 50 Hz
supply
7 Describe with sketches three different ways of starting a single-phase induction motor
12 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
8 Explain with the aid of a sketch the action of a three-phase DOL starter
What are dashpots used for How are remote start and stop buttons connected
9 A I0 kW 240V 50Hz single-phase cage rotor induction motor is 85efficient and has a PF of 068
lagging Calculate the motor current and the value of capacitor required to raise the PF to 093
lagging
10 Calculate the torque developed by an 18 kW four-pole induction motor run at 35 slip from a
50Hz supply
APPENDIX 1
13 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 11
14 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 111
Attachment Reference
httpswwwtlc-directcoukBook621htm
httpwwwstgovmyindexphpms
15 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
A first aid box has to be provided by the building owner construction site supervisor or brought
personally by the worker under the supervision of the responsible person
65 Training Programme
The management shall conduct periodic training programmes for the workers with regards to work
safety on aspects including the following -
i Dangers of electrical work being undertaken and how to control those dangers
ii The safety regulations set for the work place and
iii First aid procedures
66 Fire Prevention
Fire Extinguisher A suitable functioning fire extinguisher to control fires has to be made available at
the work place at all times
67 Competent Person
The Electricity Regulations 1994 require that all electrical work has to be undertaken by or under the
direct supervision of a competent person registered with the Energy Commission Besides that the
electrical contractor undertaking the electrical work has also to be registered with the Energy
Commission The installation owner thus has to ensure that the appointed electrical contractor is
registered with the Energy Commission and that the registration is still valid
INSTALLATION CIRCUITS AND SYSTEMS1 Block diagrams
These show using squares rectangles etc the sequence of a system without too much technical detail
eg Figures 1517 and 1526
2 Layout diagrams
These are very similar to block diagrams but they indicate more technical detail and tend to show
items in their correct geographical location (eg Figures 1518 and 1519)
3 Circuitschematic
These show how a circuit functions and takes no account of exact locations of terminals or equipment
(eg Figures 1528 1529 1532 1534 etc)
4 Wiring diagram
These indicate how a circuit or system is physically wired (eg Figures 152 154 156 etc)
Most induction motors are started directly on line but when very large motors are started that way
they cause a disturbance of voltage on the supply lines due to large starting current surges To limit the
starting current surge large induction motors are started at reduced voltage and then have full supply
voltage reconnected when they run up to near rotated speed Two methods are used for reduction of
starting voltage are star delta starting and auto transformer stating
20 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Working Principal of Star-Delta Starter
This is the reduced voltage starting method Voltage reduction during star-delta starting is achieved by
physically reconfiguring the motor windings as illustrated in the figure below During starting the
motor windings are connected in star configuration and this reduces the voltage across each winding 3
This also reduces the torque by a factor of three After a period of time the winding are reconfigured as
delta and the motor runs normally
StarDelta starters are probably the most common reduced voltage starters They are used in
an attempt to reduce the start current applied to the motor during start as a means of reducing the
disturbances and interference on the electrical supply
Traditionally in many supply regions there has been a requirement to fit a reduced voltage
starter on all motors greater than 5HP (4KW) The StarDelta (or WyeDelta) starter is one of the
lowest cost electromechanical reduced voltage starters that can be applied
The StarDelta starter is manufactured from three contactors a timer and a thermal overload
The contactors are smaller than the single contactor used in a Direct on Line starter as they are
controlling winding currents only The currents through the winding are 1root 3 (58) of the
current in the line
There are two contactors that are close during run often referred to as the main contractor and
the delta contactor These are AC3 rated at 58 of the current rating of the motor The third
contactor is the star contactor and that only carries star current while the motor is connected in star
The current in star is one third of the current in delta so this contactor can be AC3 rated at one
third (33) of the motor rating
Star-delta Starter Consists following units
1) Contactors (Main star and delta contactors) 3 Norsquos (For Open State Starter) or 4 Norsquos (Close
Transient Starter)
2) Time relay (pull-in delayed) 1 No
3) Three-pole thermal over current release 1No
4) Fuse elements or automatic cut-outs for the main circuit 3 Nos
5) Fuse element or automatic cut-out for the control circuit 1No
Power Circuit of Star Delta Starter
1 The main circuit breaker serves as the main power supply switch that supplies electricity to the
power circuit
2 The main contactor connects the reference source voltage R Y B to the primary terminal of the
motor U1 V1 W1
21 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
3 In operation the Main Contactor (KM3) and the Star Contactor (KM1) are closed initially and
then after a period of time the star contactor is opened and then the delta contactor (KM2) is
closed The control of the contactors is by the timer (K1T) built into the starter The Star and Delta
are electrically interlocked and preferably mechanically interlocked as well In effect there are
four states
4 The star contactor serves to initially short the secondary terminal of the motor U2 V2 W2 for the
start sequence during the initial run of the motor from standstill This provides one third of DOL
current to the motor thus reducing the high inrush current inherent with large capacity motors at
startup
5 Controlling the interchanging star connection and delta connection of an AC induction motor is
achieved by means of a star delta or wye delta control circuit The control circuit consists of push
button switches auxiliary contacts and a timer
Control Circuit of Star-Delta Starter (Open Transition)
1 The ON push button starts the circuit by initially energizing Star Contactor Coil (KM1) of star
circuit and Timer Coil (KT) circuit
2 When Star Contactor Coil (KM1) energized Star Main and Auxiliary contactor change its
position from NO to NC
3 When Star Auxiliary Contactor (1)( which is placed on Main Contactor coil circuit )became
NO to NC itrsquos complete The Circuit of Main contactor Coil (KM3) so Main Contactor Coil
energized and Main Contactorrsquos Main and Auxiliary Contactor Change its Position from NO
To NC This sequence happens in a friction of time
4 After pushing the ON push button switch the auxiliary contact of the main contactor coil (2)
which is connected in parallel across the ON push button will become NO to NC thereby
providing a latch to hold the main contactor coil activated which eventually maintains the
control circuit active even after releasing the ON push button switch
5 When Star Main Contactor (KM1) close its connect Motor connects on STAR and itrsquos
connected in STAR until Time Delay Auxiliary contact KT (3) become NC to NO
6 Once the time delay is reached its specified Time the timerrsquos auxiliary contacts (KT)(3) in
Star Coil circuit will change its position from NC to NO and at the Same Time Auxiliary
contactor (KT) in Delta Coil Circuit(4) change its Position from NO To NC so Delta coil
energized and Delta Main Contactor becomes NO To NC Now Motor terminal connection
change from star to delta connection
7 A normally close auxiliary contact from both star and delta contactors (5amp6)are also placed
opposite of both star and delta contactor coils these interlock contacts serves as safety
switches to prevent simultaneous activation of both star and delta contactor coils so that one
22 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
cannot be activated without the other deactivated first Thus the delta contactor coil cannot be
active when the star contactor coil is active and similarly the star contactor coil cannot also
be active while the delta contactor coil is active
8 The control circuit above also provides two interrupting contacts to shutdown the motor
The OFF push button switch break the control circuit and the motor when necessary The
thermal overload contact is a protective device which automatically opens the STOP Control
circuit in case when motor overload current is detected by the thermal overload relay this is to
prevent burning of the motor in case of excessive load beyond the rated capacity of the motor
is detected by the thermal overload relay
9 At some point during starting it is necessary to change from a star connected winding to a
delta connected winding Power and control circuits can be arranged to this in one of two
ways ndash open transition or closed transition
What is Open or Closed Transition Starting
(1) Open Transition Starters
Discuss mention above is called open transition switching because there is an open state between
the star state and the delta state
In open transition the power is disconnected from the motor while the winding are reconfigured via
external switching
When a motor is driven by the supply either at full speed or at part speed there is a rotating
magnetic field in the stator This field is rotating at line frequency The flux from the stator field
induces a current in the rotor and this in turn results in a rotor magnetic field
When the motor is disconnected from the supply (open transition) there is a spinning rotor within
the stator and the rotor has a magnetic field Due to the low impedance of the rotor circuit the time
constant is quite long and the action of the spinning rotor field within the stator is that of a
generator which generates voltage at a frequency determined by the speed of the rotor When the
motor is reconnected to the supply it is reclosing onto an unsynchronized generator and this result
in a very high current and torque transient The magnitude of the transient is dependent on the
phase relationship between the generated voltage and the line voltage at the point of closure can
be much higher than DOL current and torque and can result in electrical and mechanical damage
Open transition starting is the easiest to implement in terms or cost and circuitry and if the timing
of the changeover is good this method can work well In practice though it is difficult to set the
necessary timing to operate correctly and disconnectionreconnection of the supply can cause
significant voltagecurrent transients
In Open transition there are Four states
23 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 OFF State All Contactors are open
2 Star State The Main [KM3] and the Star [KM1] contactors are closed and the delta [KM2]
contactor is open The motor is connected in star and will produce one third of DOL torque at one
third of DOL current
3 Open State This type of operation is called open transition switching because there is an
open state between the star state and the delta state The Main contractor is closed and the Delta
and Star contactors are open There is voltage on one end of the motor windings but the other end
is open so no current can flow The motor has a spinning rotor and behaves like a generator
4 Delta State The Main and the Delta contactors are closed The Star contactor is open The
motor is connected to full line voltage and full power and torque are available
(2) Closed Transition StarDelta Starter
There is a technique to reduce the magnitude of the switching transients This requires the use of a
fourth contactor and a set of three resistors The resistors must be sized such that considerable
current is able to flow in the motor windings while they are in circuit
The auxiliary contactor and resistors are connected across the delta contactor In operation just
before the star contactor opens the auxiliary contactor closes resulting in current flow via the
resistors into the star connection Once the star contactor opens current is able to flow round
through the motor windings to the supply via the resistors These resistors are then shorted by the
delta contactor If the resistance of the resistors is too high they will not swamp the voltage
generated by the motor and will serve no purpose
In closed transition the power is maintained to the motor at all time This is achieved by
introducing resistors to take up the current flow during the winding changeover A fourth
contractor is required to place the resistor in circuit before opening the star contactor and then
removing the resistors once the delta contactor is closed These resistors need to be sized to carry
the motor current In addition to requiring more switching devices the control circuit is more
complicated due to the need to carry out resistor switching
In Close transition there are Four states
1 OFF State All Contactors are open
2 Star State The Main [KM3] and the Star [KM1] contactors are closed and the delta [KM2]
contactor is open The motor is connected in star and will produce one third of DOL torque at one
third of DOL current
Star Transition State The motor is connected in star and the resistors are connected across the
delta contactor via the aux [KM4] contactor
24 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Closed Transition State The Main [KM3] contactor is closed and the Delta [KM2] and Star
[KM1] contactors are open Current flows through the motor windings and the transition resistors
via KM4
Delta State The Main and the Delta contactors are closed The transition resistors are shorted out
The Star contactor is open The motor is connected to full line voltage and full power and torque
are available
Effect of Transient in Starter (Open Transient starter)
It is Important the pause between star contactor switch off and Delta contactor switch is on correct
This is because Star contactor must be reliably disconnected before Delta contactor is activated It
is also important that the switch over pause is not too long
For 415v Star Connection voltage is effectively reduced to 58 or 240v The equivalent of 33
that is obtained with Direct Online (DOL) starting
If Star connection has sufficient torque to run up to 75 or 80 of full load speed then the motor
can be connected in Delta mode
When connected to Delta configuration the phase voltage increases by a ratio of V3 or 173 The
phase currents increase by the same ratio The line current increases three times its value in star
connection
During transition period of switchover the motor must be free running with little deceleration
While this is happening ldquoCoastingrdquo it may generate a voltage of its own and on connection to the
supply this voltage can randomly add to or subtract from the applied line voltage This is known as
transient current Only lasting a few milliseconds it causes voltage surges and spikes Known as
a changeover transient
Size of each part of Star-Delta starter
(1) Size of Over Load Relay
For a star-delta starter there is a possibility to place the overload protection in two positions in the
line or in the windings
Overload Relay in Line
In the line is the same as just putting the overload before the motor as with a DOL starter
The rating of Overload (In Line) = FLC of Motor
Disadvantage If the overload is set to FLC then it is not protecting the motor while it is in delta
(setting is x1732 too high)
Overload Relay in Winding
25 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
In the windings means that the overload is placed after the point where the wiring to the contactors
are split into main and delta The overload then always measures the current inside the windings
The setting of Overload Relay (In Winding) =058 X FLC (line current)
Disadvantage We must use separate short circuit and overload protections
(2) Size of Main and Delta Contractor
1 There are two contactors that are close during run often referred to as the main contractor and
the delta contactor These are AC3 rated at 58 of the current rating of the motor
Size of Main Contactor= IFL x 058
(3) Size of Star Contractor
The third contactor is the star contactor and that only carries star current while the motor is
connected in star The current in star is 1 radic3= (58) of the current in delta so this contactor can
be AC3 rated at one third (33) of the motor rating
Size of Star Contactor= IFL x 033
Motor Starting Characteristics of Star-Delta Starter
Available starting current 33 Full Load Current
Peak starting current 13 to 26 Full Load Current
Peak starting torque 33 Full Load Torque
Advantages of Star-Delta starter
The operation of the star-delta method is simple and rugged
It is relatively cheap compared to other reduced voltage methods
Good TorqueCurrent Performance
It draws 2 times starting current of the full load ampere of the motor connected
Disadvantages of Star-Delta starter
Low Starting Torque (Torque = (Square of Voltage) is also reduce)
Break In Supply ndash Possible Transients
Six Terminal Motor Required (Delta Connected)
It requires 2 set of cables from starter to motor
It provides only 33 starting torque and if the load connected to the subject motor requires higher
starting torque at the time of starting than very heavy transients and stresses are produced while
changing from star to delta connections and because of these transients and stresses many
electrical and mechanical break-down occurs
26 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
In this method of starting initially motor is connected in star and then after change over the motor
is connected in delta The delta of motor is formed in starter and not on motor terminals
High transmission and current peaks When starting up pumps and fans for example the load
torque is low at the beginning of the start and increases with the square of the speed When
reaching approx 80-85 of the motor rated speed the load torque is equal to the motor torque and
the acceleration ceases To reach the rated speed a switch over to delta position is necessary and
this will very often result in high transmission and current peaks In some cases the current peak
can reach a value that is even bigger than for a DOL start
Applications with a load torque higher than 50 of the motor rated torque will not be able to start
using the start-delta starter
Low Starting Torque The star-delta (wye-delta) starting method controls whether the lead
connections from the motor are configured in a star or delta electrical connection The initial
connection should be in the star pattern that results in a reduction of the line voltage by a factor of
1radic3 (577) to the motor and the current is reduced to 13 of the current at full voltage but the
starting torque is also reduced 13 to 15 of the DOL starting torque
The transition from star to delta transition usually occurs once nominal speed is reached but is
sometimes performed as low as 50 of nominal speed which make transient Sparks
Features of star-delta starting
1 For low- to high-power three-phase motors
2 Reduced starting current
3 Six connection cables
4 Reduced starting torque
5 Current peak on changeover from star to delta
6 Mechanical load on changeover from star to delta
Application of Star-Delta Starter
The star-delta method is usually only applied to low to medium voltage and light starting
Torque motors
The received starting current is about 30 of the starting current during direct on line start and the
starting torque is reduced to about 25 of the torque available at a DOL start This starting
method only works when the application is light loaded during the start If the motor is too heavily
27 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
loaded there will not be enough torque to accelerate the motor up to speed before switching over
to the delta position
LESSON 1 WIRING SYSTEM OF SINGLE PHASE DISTRIBUTION BOARD
Introduction
28 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
29 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
30 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
31 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 2 WIRING SYSTEM OF SINGLE PHASE LIGHTING CIRCUIT Introduction
Objectives
1 Identify component and the specification
2 Wire component according to the schematic diagram
3 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Wiring bay Perforated metal 180 cm x 180 cm 1
2 Cut out fuse 63 A 240 V 1
3 Neutral link 1
4 Single pole one way switch cw
switch box
5A 240Vac 4
5 single pole two way switch cw
switch box
5A 240Vac 2
6 RCCB In = 40 A Tripping current
100mA240 Vac 50 Hz
1
7 Main switch 32 A 240V 1
8 kWatthour meter 40 A 240 Vac 1
9 Single pole MCB 6A 240 Vac 1
10 Self tapping Wood screw As required
11 DIN rail 35 mm width As required
32 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
12 PVC trunking 50 mm x 50 mm As required
13 Terminal blocks 5 A As required
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
1 One way switch to control one lamp
2 One way switch to control two lamps
3 Two of two way switch to control one lamp
4 Two of single pole two way switch and one of an intermediate switch to control one
lamp
5 One unit of ceiling fan and fan regulator to be controlled by one way switch
4 Test the functionality of completed project
LESSON 3ndash WIRING SYSTEM OF SINGLE PHASE POWER CIRCUIT Introduction
33 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
34 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify types of component and its specification
2 Wire component according to the schematic diagram given
3 Test the functionality of the circuit dead circuit test life circuit test
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board Perforated Metal 1
2 kWh meter 240 V 40 A 1
3 Socket outlet 13A 240Vac 4
4 RCCB 40A Trip Amps
30mA240 Vac
1
5 3 pin socket 240Vac 13A 4
6 Single pole MCB 20A 240 V 2
7 DOL starter 1 kW 240Vac 2
8 1 phase induction motor 2Hp 240 Vac 1
9 Cooker control unit 4kW 240Vac 1
10 Water heater point 4kW 240 Vac 1
11 DIN rail 35 mm As required
12 PVC casing 20mm As required
13 Flexible wires 05 mm As required
14 Terminal block 10 A As required
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Wire two unit of 13 A socket outlet in radial circuit
3 Wire four units of 13 A socket outlet in ring circuit
4 Wire one unit DOL starter for air-conditioner point
5 Wire one unit of cooker control unit point
6 Wire one unit of water heater point
7 Test the functionality of each component by using mmeter or power supply whichever
applicable
8 Wire component according to circuit diagram
9 Test the functionality of completed project dead circuit test life circuit test
Note
35 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Ensure that the correct rating of protection device and size of wire used
LESSON 4ndash CONDUIT BENDING AND TRUNKING FABRICATION TECHNIQUE
Common fitting used in an industrial wiring
Cutting and threading the condute
36 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
37 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
38 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify conduit fitting and the specification
2 Measure and Cut steel conduit according to specified dimension
3 Bend and fabricate conduit at 45 90 according to layout diagram
4 Wire component according to the schematic diagram
5 Test the functionality of the circuit
39 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Conduit Bender Oslash 19 mm ( frac34 ldquo) 1
2 Measuring Tape 3 metre 1
3 Hacksaw frame and blade 30cm 1
4 Conduit cutter 1
5 Pipe Vise 1
6 Pipe Wrench 1
7 Ratchet Dies 20 mm 1
8 Metal trunking 50 mm x 50 mm 1
9 GI conduit 20mm 1
10 End box 20 mm 1
11 Flexible wires 05 mm As required
12 Connectors 5 A As required
13 Single core PVC ins Cable 25 mm 2 As required
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Wire two unit of 13 A socket outlet in radial circuit
3 Wire four unit of 13 A socket outlet in ring circuit
4 Wire one unit DOL starter for air-conditioner point
5 Wire one unit of cooker control unit point
6 Wire one unit of water heater point
7 Test the functionality of each component by using multimeter or power supply whichever
applicable
8 Wire component according to circuit diagram
9 Test the functionality of completed project
Note
Ensure that the rating of protection device and size of wire
K prior to 31 March
2004 (BS 7671)
(formerly)
bare conductor
sleeved at terminations (formerly)
40 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 5 ndashWIRING SYSTEM OF 1 Oslash LIGHTING AND POWER CIRCUIT
POWER CIRCUITSa Radial circuits
Radial circuits are arranged in the same way as item 1 above in lighting layouts in that each socket
outlet is supplied via the previous one
Points to note
1 The number of socket outlets complying with BS 1363 is unlimited for a floor area of up to 50m 2 if
the circuit protection is a 30 A or 32 A cartridge fuse or circuit breaker the cable being 4 mm PVC
copper or 25 mm2 mineral insulated (mi)
2 The number of socket outlets is unlimited for a floor area up to 20 m 2 with any type of circuit
protection of 20 A using 25 mm2 PVC copper cable or 15 mm2 mi
3 The total number of fused spurs is unlimited
b ring final circuits
These circuits are the same as radial circuits except that the final socket outlet is wired back to the
supply position In effect any outlet is supplied from two directions (Fig 152)
Points to note
1 Every twin-socket outlet counts as two single-socket outlets
2 The number of non-fused spurs must not exceed the total number of points on the ring Fig 158
shows seven points on the ring and five spurs
3 The fuse rating of a fused spur box must not exceed 13 A and the current rating of all points supplied
by the fused spur must not exceed 13 A
4 Non-fused spurs must supply no more than one single or one double socket on the ring Fig 158
shows seven points on the ring and five spurs rating of all points supplied by the fused spur must not
exceed 13 A or one stationary appliance
CapacityMain conductor size
copper (mm2)
Earth conductor
size (mm2)
Circuit breaker
capacity (A)
Up to 600 W 15 15 6
600ndash1200 W 1525 15 10
1200ndash1800 W 254 25 16
41 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Ring circuit
(floor area 100 m2)25 15 3032
A2 radial circuit
(floor area 75 m2)40 25 3032
A3 radial circuit
(floor area 50 m2)25 15 20
Air conditioner (15 tonne) 60 60 3032
Cooker 60 60 3032
Water heater 40 40 20
Objectives
1 Identify component and the specification
2 Wire component according to the schematic diagram
3 Test the functionality of the circuit
42 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board Perforated 1
2 Cut out fuse and neutral link 60A 240V 1each
3 kWh meter 240V 40A 1
4 Switched Socket outlet 13A 240Vac 4
5 Single pole two way switch cw switch
box
5A 240Vac 2
6 RCCB ELCB 63 A Tripping current 100mA
415 Vac
1
7 3 pin plug 240Vac 13A 4
8 Single pole MCB 20 A 2
9 Single pole MCB 6A 1
10 Single pole MCB 20A 2
11 DOL starter 240Vac 2
12 1 phase induction motor 2hp 240 Vac 1
13 Self tapping Wood screw As required
14 DIN rail Stainless steel allum35 mm As required
15 PVC pipe 20mm dia As required
16 End box 20 mm dia 4
17 Flexible wires 05 mm 2 As required
18 Connectors 5 A As required
Procedures
43 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
4 Test the functionality of completed project
LESSON 6 ndash WIRING SYSTEM OF 3 Oslash DISTRIBUTION BOARD
Introduction
44 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
45 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
46 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
47 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
48 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify each component and the specification
2 Wire component according to the schematic diagram given
3 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting Board 450 x 600 mm Perforated metal 1
2 5 pin round socket and plug 415V ac 32A 1
3 Cut out fuse 60 A 3
4 Neutral link 1
5 kWatt hour meter 415V 60A 1
6 ELCB RCCB 3P+N In=63A415 Vac I trip= 300mA 1
7 ELCB RCCB 3P+N In=63A415 Vac I trip= 30mA 1
8 Single pole MCB 6A 240 V 3
9 Single pole MCB 20A 240 V 3
10 DOL starter 20 A 240Vac 2
11 Socket outlet 15 A 240 Vac 1
12 Switched Socket outlet 13 A 240 Vac 3
13 Led indicating light 5A 240 Vac 3
14 Single pole 4 gang 1 way switch 5A 240 Vac 2
15 Single pole 2 way switch 5A 240 Vac 2
16 1 phase induction motor 1 kW 240Vac 1
17 Metal trunking 30 mm x30 mm As required
18 Self tapping Wood screw 4 mm x 20 mm As required
19 DIN rail 25 mm x 1mm
20 GI steel rigid conduit 20mm As required
21 Flexible conduit 20mm As required
22 End box 20 mm 4
23 Flexible wires 05 mm 2 As required
24 Single core PVC insulated wire 15 mm 2 As required
25 Single core PVC insulated wires 25 mm 2 As required
26 Terminal block 10 A As required
Procedures
49 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify each components and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
4 Test the functionality of completed project
1 dead circuit test
2 life circuit
Note Proper earthing should be made
50 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 7 ndash WIRING SYSTEM OF THREE PHASE LIGHTING AND POWER CIRCUIT
51 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
52 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify component and the specification
2 Wire component according to the schematic diagram
3 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting bay Board Perforated metal 180 cm x 180 cm 1
2 k Watt hour meter 415V 60A 1
3 MCCB 415V 60A
4 ELCB RCCB In=60A415 Vac I trip=30mA 1
5 5 pin round Socket and
plug
415Vac 32A 4
6 Single pole MCB 6A 1
7 Triple pole MCB 20A 2
8 Triple pole Main switch 60A 1
9 DOL starter 240Vac 2
10 3 phase induction motor 2hp 415 Vac 1
11 1 phase induction motor 1
12 Metal trunking 30 mm x30 mm As required
13 Self tapping Wood screw 4 mm x 20 mm As required
14 DIN rail 25 mm x 1mm
15 GI steel rigid conduit 20mm As required
16 Flexible conduit 20mm As required
17 End box 20 mm 4
18 Flexible wires 05 mm As required
19 Connectors 10 A As required
Procedures
1 Identify each components and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
4 Test the functionality of completed project
1 dead circuit 2 life circuit test
5 Record the current drawn by the load as connected in star and delta
Note Proper earthing should be made
53 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 8 INSPECTION AND TESTING OF ELECTRICAL INSTALLATION
On completion of a wiring installation a number of tests on the installation have to be conducted to
ascertain that the wiring circuits and connected appliances are safe for use Prior to carrying out the
tests an inspection has to be done The results of the inspectionsupervision and test have to be
presented in Form G (as in Appendix IV) and Form H (as in Appendix V)
To have the test certification as in Form H the following tests shall be conducted
i Continuity Test
ii Insulation Resistance Test
iii Polarity Test
iv Earth Electrode Resistance test and
v Residual Current Device Test
1 Continuity Test
There are 3 main types of continuity tests for the final circuits-
i Protection Conductor Continuity Test
ii Final Ring Circuit Conductor Continuity Test
iii Live and Neutral Conductor Continuity Test
a) Protection Conductor Continuity Test
bull To ascertain that all protection conductors are connected in the correct and effective manner
bull Test equipment ndash Multimeter (Ohm range) or Ohm meter
54 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
bull Test Method
1 1048766 Ensure that the main switch RCD and MCB are open circuited (switched off) and all loads
are disconnected
2 1048766 Connected the test leads as in the Figure 81 The meter reading shall be less than 1 Ω
55 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Final Ring Circuit Conductor Continuity Test
bull To ensure that all conductors around the ring circuit have continuity
bull Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
bull Test Method
1 1048766 Disconnect both the supply source live conductors from the MCB the neutral conductor
from the neutral terminals and the earth conductor from the earth terminal in the distribution
fuse box
2 1048766 Connect the test leads as in the Figure 82 (EE)
3 1048766 Repeat the procedure for (L-L) and (N-N)
4 1048766 The meter reading value shall be less than 1 ohm
56 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Live and Neutral Conductor Continuity Test
a To ensure that each conductor in the circuit has continuity
b Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
2 Test Method
1 1048766 Switch off the Main switch RCD and MCB
2 1048766 Disconnect all loads
3 1048766 Switch on all switches in the circuit
4 1048766 Disconnect the fusesfinal circuit breakers and close the circuit
5 1048766 Carry out the test as shown in Figure 83
6 1048766 The meter reading value shall be less than 1Ω
57 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
58 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
CONTINUITY TEST
Insulation Resistance Test
i Ensure that there is no leakage current between phase conductors phase and neutral conductors and
phase conductor and earth
ii Test the strength of the cable insulation
iii Test Equipment ndash Insulation Resistance Tester operating voltage is 250VDC or 500VDC
iv Test Method
1 1048766 Switch off main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
59 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
4 1048766 Carry out test as in the Table below
5 1048766 Meter reading value shall be less than 1 Megaohm
60 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
61 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Insulation resitance test
62 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
INSULATION RESISTANCE TEST BETWEEN CONDUCTORS AND OPPOSITE POLARITY
Polarity Testi Ensure that each fuse or single pole control and protection device is connected only in the phase
conductor
ii Intermediate contact of Edison screw lamp holder is connected to the phase conductor
iii Ensure that phase neutral and earth conductors at socket outlets are connected at the correct
terminals
iv Test Equipment ndash Multimeter (Ohm range) or Ohm meter
v Test Method
1 1048766 Switch off Main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in Figure 85
63 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
5 1048766 Test switches and single phase control devices at the phase conductors
6 1048766 Test socket outlet connection sources
7 1048766 Test Edison screw lamp holder connections
8 1048766 Meter reading value shall be less than 1 Ω
64 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Polarity test
65 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Earth Electrode Resistance Testi To test the earth electrode resistance
ii To ascertain the suitability of the location of the electrode
iii To ensure that the electrode is not buried within the resistance area of another electrode
iv Test equipment ndash Earth Resistance Tester
v Test method -
1 1048766 Terminal rsquoErsquo is connected to the electrode to be tested (green conductor)
2 1048766 Terminal lsquoPrsquo is connected to the potential spike (yellow conductor) at a distance of 10
meters from the earth electrode
3 1048766 Terminal lsquoCrsquo is connected to the current spike (red conductor) at a distance of 20 meters
from the earth electrode
Earth Electrode Resistance Measurement Method (Figure 86)
This test must be repeated at least three times to ensure that the reading is not affected by interacting
earthing regions
i Record the first reading (Z1) Example Z1 = 10 Ω
ii Move the voltage spike to a distance of 6 meters from the original position Record the second
reading (Z2 ) Example Z2 = 10 Ω
iii Move the voltage spike to a distance of 6 meters from the original position Record the third
reading (Z3) Example Z3 = 10 Ω
66 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Residual Current Device Testi Ensure that the residual current device (RCD) trips within the set time on the occurrence of current
leakage to earth
ii Test Equipment ndash RCD Tester RCCB Tester
iii Test Method 1
1 1048766 Use the Trip Test Button
2 1048766 Press the trip button found on the RCD to determine if it trips or otherwise This test would
not be able to determine the sensitivity of the RCD nor the time taken for it to trip
iv Test Method 2
i 1048766 Use a RCD Tester
ii This equipment is equipped with a 13A plug which can be connected to a 13A socket outlet
Select the RCD sensitivity to be the same as the sensitivity of the RCD to be tested to
determine if the RCD can trip The time to trip shall not exceed 40 mS
iii 1048766 Test method ndash
a) Position the selection switch in accordance with the sensitivity of the RCD used
Example 100 mA 01 A
b) Position the operations switch to lsquoNo Triprsquo (frac12 Rated mA = 50) connect the 3 pin plug to
the 13A socket outlet
67 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
c) Switch on the 13A socket outlet ndash ensure that the P-N and P-E lights light up
This shows that the polarity is correct (Note if both the lights as above do not light up the test cannot
be continued)
d) Press the test button ndash the reading shows less than 200 mS and simultaneously the lsquotestrsquo light lights
up and the P-N and P-E lights do not light up At that instant the RCD will not trip
e) Move the selection switch to 180o (+ve wave) ndash repeat steps (d) and (e) Move the operations
switch to lsquoTriprsquo (Rated mA = 100)
g) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200mS
h) Move the selection switch to 0o (-ve wave)
i) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
j) The above test is repeated until a near correct reading is obtained
k) Record the test results
l) Change the operations switch to lsquoFast Triprsquo and press the test button ndash RCD will trip within a
time not exceeding 40 millisecond
m) Repeat a number of times at 0o or 180o
On completion of a wiring installation a number of tests on the installation have to be conducted to
ascertain that the wiring circuits and connected appliances are safe for use Prior to carrying out the
tests an inspection has to be done the following tests shall be conducted
i Continuity Test
ii Insulation Resistance Test
iii Polarity Test
iv Earth Electrode Resistance test and
v Residual Current Device Test
821 Continuity Test
There are 3 main types of continuity tests for the final circuits-
i Protection Conductor Continuity Test
ii Final Ring Circuit Conductor Continuity Test
68 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
iii Live and Neutral Conductor Continuity Test
a) Protection Conductor Continuity Test
bull To ascertain that all protection conductors are connected in the correct and effective manner
bull Test equipment ndash Multimeter (Ohm range) or Ohm meter
bull Test Method
1 1048766 Ensure that the main switch RCD and MCB are open circuited (switched off) and all loads are
disconnected
2 1048766 Connected the test leads as in the Figure 81
3 1048766 The meter reading shall be less than 1 Ω
Final Ring Circuit Conductor Continuity Test
bull To ensure that all conductors around the ring circuit have continuity
bull Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
bull Test Method
1 1048766 Disconnect both the supply source live conductors from the MCB the neutral conductor
from the neutral terminals and the earth conductor from the earth terminal in the distribution
fuse box
2 1048766 Connect the test leads as in the Figure 82 (EE)
3 1048766 Repeat the procedure for (L-L) and (N-N)
4 1048766 The meter reading value shall be less than 1 ohm Figure 82 - Final Ring Circuit Conductor
Continuity Test Ohm Meter
Disconnect both the supply source cables from mcbfuse
Take readings at earth conductors of both sources and note resistance readings
Live and Neutral Conductor Continuity Test
1 To ensure that each conductor in the circuit has continuity
2 Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
3 Test Method
1 1048766 Switch off the Main switch RCD and MCB
2 1048766 Disconnect all loads
3 1048766 Switch on all switches in the circuit
4 1048766 Disconnect the fusesfinal circuit breakers and close the circuit
5 1048766 Carry out the test as shown in Figure 83
6 1048766 The meter reading value shall be less than 1 ohm Figure 83 - Live and Neutral
Conductor Continuity Test Ohm Meter
Insulation Resistance Test
69 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
i Ensure that there is no leakage current between phase conductors phase and neutral conductors and
phase conductor and earth
ii Test the strength of the cable insulation
iii Test Equipment ndash Insulation Resistance Tester Operating voltage is 250VDC or 500VDC
iv Test Method
1 1048766 Switch off main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in the Table below
5 1048766 Meter reading value shall be less than 1 Megaohm
Polarity Test
i Ensure that each fuse or single pole control and protection device is connected only in the phase
conductor
ii Intermediate contact of Edison screw lamp holder is connected to the phase conductor
iii Ensure that phase neutral and earth conductors at socket outlets are connected at the correct
terminals
iv Test Equipment ndash Multimeter (Ohm range) or Ohm meter
v Test Method
1 1048766 Switch off Main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in Figure 85
5 1048766 Test switches and single phase control devices at the phase conductors
6 1048766 Test socket outlet connection sources
7 1048766 Test Edison screw lamp holder connections
8 1048766 Meter reading value shall be less than 1 Ω
Earth Electrode Resistance Test
i To test the earth electrode resistance
70 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
ii To ascertain the suitability of the location of the electrode
iii To ensure that the electrode is not buried within the resistance area of another electrode
iv Test equipment ndash Earth Resistance Tester
v Test method -
1 1048766 Terminal rsquoErsquo is connected to the electrode to be tested (green conductor)
2 1048766 Terminal lsquoPrsquo is connected to the potential spike (yellow conductor) at a distance of 10
meters from the earth electrode
3 1048766 Terminal lsquoCrsquo is connected to the current spike (red conductor) at a distance of 20 meters
from the earth electrode E P C Electrode 10 meter 10 meter
Figure 86 ndash Earth Electrode Resistance Measurement Test Equipment
Earth Electrode Resistance Measurement Method (Figure 86)
This test must be repeated at least three times to ensure that the reading is not affected by interacting
earthing regions
i Record the first reading (Z1) Example Z1 = 10 Ω
ii Move the voltage spike to a distance of 6 meters from the original position Record the second
reading (Z2) Example Z2 = 10 Ω
iii Move the voltage spike to a distance of 6 meters from the original position Record the third
reading (Z3)
Example Z3 = 10 Ω
Residual Current Device Test
71 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
i Ensure that the residual current device (RCD) trips within the set time on the occurrence of current
leakage to earth
ii Test Equipment ndash RCD Tester RCCB Tester
iii Test Method 1
1 1048766 Use the Trip Test Button
2 1048766 Press the trip button found on the RCD to determine if it trips or otherwise This test would
not be able to determine the sensitivity of the RCD nor the time taken for it to trip
iv Test Method 2
1048766 Use a RCD Tester
This equipment is equipped with a 13A plug which can be connected to a 13A socket outlet Select the
RCD sensitivity to be the same as the sensitivity of the RCD to be tested to determine if the RCD can
trip The time to trip shall not exceed 40 mS
1048766 Test method ndash
a) Position the selection switch in accordance with the sensitivity of the RCD used
Example 100 mA 01 A
b) Position the operations switch to lsquoNo Triprsquo (frac12 Rated mA = 50) connect the 3 pin plug to
the 13A socket outlet
c) Switch on the 13A socket outlet ndash ensure that the P-N and P-E lights light up This shows that
the polarity is correct (Note if both the lights as above do not light up the test cannot be
continued)
d) Press the test button ndash the reading shows less than 200 millisecond and simultaneously the
lsquotestrsquo light lights up and the P-N and P-E lights do not light up At that instant the RCD will
not trip
e) Move the selection switch to 180o (+ve wave) ndash repeat steps (d) and (e) = 100)
f) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
g) Move the selection switch to 0o (-ve wave)
h) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
i) The above test is repeated until a near correct reading is obtained
j) Record the test results
k) Change the operations switch to lsquoFast Triprsquo and press the test button ndash RCD will trip within a
time not exceeding 40 mS
l) Repeat a number of times at 0o or 180o
72 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 9 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (DC)
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
73 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Start stop button 240Vac 5A 2
9 Filament lamp (Bulb ) 240Vac 40W 3
10 Overload Relay 415V 20A 3
11 Three phase induction motor 5 hp 3
12 Single phase step down transformer 2500VA 1
13 Single core PVC insulated Cable 1mm 2 As required
14 Single core PVC insulated Cable 25mm 2 As required
15 DIN rail 35 mm As required
16 PVC type Cable tray 50 mm x 50 mm As required
17 Cable ties 4 ldquo As required
18 Flexible wires 05 mm As required
19 PVC Connectors 5 A amp 20 A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the schematic
diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a optional exercise
i Simple DOL starter
ii Forward reverse DOL starter
iii Forward Reverse Dahlander motor
iv Three motors operated in sequence by DOL starter operated by manual push
button or time delay relay
74 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
a One loop per-cycle
b Continuous operation in a loop
c optional circuit design to represent the same task
v Only one out of three motors to be operated at a time (quiz)
4 Test the functionality of completed project
LESSON 10 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (AC)
75 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 1
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Lamp point 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
76 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
11 Overload Relay 415V 20A 3
12 Three phase induction
motor
5 hp 3
13 Single core PVC insulated
Cable
1mm 2 As required
14 Single core PVC insulated
Cable
25mm 2 As required
15 DIN rail 35 mm As required
16 PVC type Cable tray 50 mm x 50 mm As required
17 Cable ties 4 ldquo As required
18 Flexible wires 05 mm As required
19 PVC Connectors 5 A amp 20 A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the
schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram optional exercise
4 Simple DOL starter
5 Forward reverse DOL starter
6 Test the functionality of completed project
77 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 1
78 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
cm
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Indicating light 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
11 Overload Relay 415V 20A 3
12 Three phase induction motor 5 hp 3
13 Single phase step down
transformer
2500VA 1
14 Single core PVC insulated
Cable
1mm 2 As required
15 Single core PVC insulated
Cable
25mm 2 As required
16 DIN rail 35 mm As required
17 PVC type Cable tray 50 mm x 50 mm As required
18 Cable ties 4 ldquo As required
19 Flexible wires 05 mm As required
20 PVC Connectors 5 A amp 20 A 240 V As required
21 Single pole MCB 6A 240 V 1
22 Single pole MCB 2A 240 V 1
23 Triple pole MCB 20A 415 V 1
24 Mounting board 30 cm x 40 cm x 3
cm
1
25 Relay cw 11 pin socket 10 A 240 Vac 2
26 Time delay relay 10 A 240 Vac 3
27 Triple pole Contactor 20A 240Vac 3
28 Batten type Lamp holder 240Vac 10 A 3
29 Start stop button 240Vac 10A 2
30 Indicating light (Bulb ) 240Vac 25W 3
31 Overload Relay 415V 20A 1
32 Three phase dahlander type
induction motor
5 hp 1
33 Single phase step down
transformer
24024Vac
2500VA
1
79 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
34 Single core PVC insulated
Cable
1mm 2 As required
35 Single core PVC insulated
Cable
25mm 2 As required
36 DIN rail 35 mm As required
37 PVC type Cable tray 50 mm x 50 mm As required
38 Cable ties 4 ldquo As required
39 Flexible wires 075 mm As required
40 PVC Connectors 5 A amp 20 A 240 V As required
41 Terminal block 20A 240Vac As required
Procedures
5 Identify each component according to specification and quantity required from the schematic
diagram attached
6 Test the functionality of each component by using multi-meter or power supply whichever
applicable
7 Wire component according to circuit diagram
8 Three motors operated in sequence by DOL starter operated by manual push button or time
delay relay
a One loop per-cycle
b Continuous operation in a loop
c optional circuit design to represent the same task
d Only one out of three motors to be operated at a time (quiz)
9 Test the functionality of completed project
80 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
BASIC DESIGN INDUSTRIAL MOTOR CONTROL (SEQUENCE CONTROL)
THREE PHASE INDUCTION MOTOR OPERATED IN SEQUENCE BY DIRECT ON LINE
STARTER
LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
81 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
82 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Lcd lamp indicator 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
11 Overload Relay 415V 20A 3
12 Three phase induction motor 5 hp 3
13 Single phase step down transformer 2500VA 1
14 Single core PVC insulated Cable 1mm 2 As required
15 Single core PVC insulated Cable 25mm 2 As required
16 DIN rail 35 mm As required
17 PVC type Cable tray 50 mm x 50 mm As required
18 Cable ties 4 ldquo As required
19 Flexible wires 1 mm Oslash As required
20 PVC Terminal block 10A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the schematic
diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a optional exercise
i Forward Reverse dahlander motor
4 Test the functionality of completed project
83 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
THREE PHASE DAHLANDER TYPE INDUCTION MOTOR OPERATED FORWARD AND
REVERSE OPERATION BY DIRECT ON LINE STARTER
84 ndash 99EASYTECH ENTERPRISE
LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
Introduction
If a motors windings are connected in the star configuration any two phases will be in series across
the supply and hence the line current will be smaller(by 577) than if the windings were connected in
the delta arrangement
Hence larger-type motors with heavy starting currents are first connected in star and then when the
starting currents fall in delta This of course means that all six of the ends of the windings must be
brought to terminations outside the casing (Fig 833)
EZTECH
EZTECH ELECTRICAL INSTALLATION GUIDE
The automatic version of this starter incorporates a timing relay which automatically changes the
connections from star to delta Figs 834 and 835 show the wiring and schematic diagrams for a star
delta starter
Objectives
1 Identify component and the specification
2 Design forward reverse star delta starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
2 ndash 99EASYTECH ENTERPRISE
REV -C
LEGENDMCCB Moulded Case Circuit BreakerTOR Thermal Over Load RelayFOW-C Mains Forward ContactorREV-C Mains Reverse ContactorDC Delta ContactorSC Star ContactorS-SW Mains Selector Switch
SC
V2
W2
U2
DC
V1
W1
U1
TOR
TOR
FOW-C
30A MCCB
TOR
MAIN CIRCUIT FORWARD REVERSE STAR DELTA
RYBN S
-SW
3 PHASEINDUCTION MOTOR
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Relay 10 A 240V 3
5 Triple pole Contactor
6 cw NO NC auxiliary contact
240Vac 20 A 4
7 Overload Relay 415 V 1
8 LED indicator 240vac 5 A 4
9 Start stop button 240Vac 5A 2
10 DIN rail 35 mm As required
11 Flexible wires 1 mm As required
12 Single core PVC insulated
wire
25 mm As required
13 Terminal block 20 A As required
14 Squirrel cage motor 5kW 1
15 5 pin plug and socket 415V 20A 1
16 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
3 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
a Manual star delta
b Manual Forward reverse star delta starter
c Automatic star delta starter
d Automatic Forward reverse star delta starter
4 Test the functionality of completed project
4 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
Objectives
1 Identify component and the specification
2 Design auto transformer starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
5 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Autotransformer starter is used to start a 3 phase induction motor that has a rating between 10 to 15 hp
6 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Autotransformer set 10Kw 415 V 50 Hz 1
5 Triple pole Contactor 240Vac 4
6 Batten type Lamp holder 240 Vac 105 A 4
7 Start stop button 240Vac 10A 4
8 Filament lamp (Bulb ) 240Vac 40W 4
9 DIN rail 35 mm As required
10 Flexible wires 1 mm As required
7 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
11 Single core PVC insulated
wire
25 mm As required
12 Terminal block 20 A As required
13 Squirrel cage motor 10kW 1
14 5 pin plug and socket 415V 20A 1
15 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a open transient autotransformer starter
b close transient autotransformer starter
c Forward reverse autotransformer starter
4 Test the functionality of completed project
8 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
Objectives
1 Identify component and the specification
2 Design rotor resistance starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
9 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Rotor Resistor set 10kW 1
5 Triple pole Contactor 240Vac 20A 4
6 Indicating light 240vac 5 A 4
7 Start stop push button 240Vac 5A 4
8 DIN rail 35 mm As required
9 Flexible wires 1 mm 2 As required
10 Single core PVC insulated wire 25 mm 2 As required
11 Terminal block 20 A As required
12 Slip Ring motor 10kW 1
13 5 pin round 3 phase socket 415V 20A 1
14 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
10 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
4 Test the functionality of completed project
a Dead circuit test b Life circuit test
5 Measure starting and running Amps
LESSON 16
TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
An installation in general will suffer damage
Damage usually occurs on the electric motor control as follows
1 Damage to the main circuit
2 Damage to the control circuit
The cause of the damage
i Overcurrent overload short circuit
ii Leakage current to ground
iii Equipment malfunction
iv The main control circuit
a Trip of main circuit protection devices fire
b Defect of motor terminal such as short circuit fire loose
v The control circuit is not functioning -
a contactor relay relay time overload relay does not work damaged burned
b Loose cable connection disconnected
Detecting and Repairing Damage
Examples of damage are as follows
i Motor does not work
ii Motor function and overload relay trips
iii Motor function but only partially functional control circuit
Methods of detecting damage
Among the known methods necessary to detect damage are as follows
1 Turn off the electricity at the main switch (main switch) in order to avoid any danger during the
work carried out to detect damage
2 Check all the protective gear that controls the motor control main circuit
11 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
3 Make sure the damage function control circuit
4 Check the control circuit according to the schematic circuit diagram of the motor control
5 Check the operation of the control circuit
Note
Use wiring that has been installed on the SYSTEM OF MOTOR CONTROL BOARD by Forward
Reverse control circuit for Star Delta to test and look for damage
SELF-ASSESSMENT QUESTIONS
1 (a) Explain what is meant by the term lsquoback emfrsquo in a motor
(b) Outline the basic differences between series shunt and compound wound dc motors
2 (a) With the aid of diagrams explain how the speed of series shunt and compound-wound motors
may be controlled
(b) A 440V dc shunt-wound motor has a field resistance of 200R and an armature resistance of 06 R
When its speed is 20 rev d second the current drawn from the supply is 122A Calculate its back
emf at this speed If the speed were decreased to 19 revssecond the field flux remaining unchanged
calculate the new back emf and the new armature current
3 A load of 64 kW at 240 V is supplied from the terminals of a shunt-wound dc generator The field
resistance is 180 A Calculate the armature current
4 (a) Explain with the aid of a diagram how a rotating magnetic field may be
(b) What is meant by lsquosynchronous speedrsquo
Calculate the synchronous obtained speed of a 12 pole motor if the supply frequency is 50Hz
5 (a) Explain the action of a synchronous motor
(b) What methods are available to start a synchronous motor Explain with diagrams
6 (a) Explain the action of a cage induction motor
(b) What is meant by the term lsquosliprsquo
Calculate the percentage slip of a six pole induction motor running at 162 revssecond from a 50 Hz
supply
7 Describe with sketches three different ways of starting a single-phase induction motor
12 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
8 Explain with the aid of a sketch the action of a three-phase DOL starter
What are dashpots used for How are remote start and stop buttons connected
9 A I0 kW 240V 50Hz single-phase cage rotor induction motor is 85efficient and has a PF of 068
lagging Calculate the motor current and the value of capacitor required to raise the PF to 093
lagging
10 Calculate the torque developed by an 18 kW four-pole induction motor run at 35 slip from a
50Hz supply
APPENDIX 1
13 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 11
14 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 111
Attachment Reference
httpswwwtlc-directcoukBook621htm
httpwwwstgovmyindexphpms
15 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Working Principal of Star-Delta Starter
This is the reduced voltage starting method Voltage reduction during star-delta starting is achieved by
physically reconfiguring the motor windings as illustrated in the figure below During starting the
motor windings are connected in star configuration and this reduces the voltage across each winding 3
This also reduces the torque by a factor of three After a period of time the winding are reconfigured as
delta and the motor runs normally
StarDelta starters are probably the most common reduced voltage starters They are used in
an attempt to reduce the start current applied to the motor during start as a means of reducing the
disturbances and interference on the electrical supply
Traditionally in many supply regions there has been a requirement to fit a reduced voltage
starter on all motors greater than 5HP (4KW) The StarDelta (or WyeDelta) starter is one of the
lowest cost electromechanical reduced voltage starters that can be applied
The StarDelta starter is manufactured from three contactors a timer and a thermal overload
The contactors are smaller than the single contactor used in a Direct on Line starter as they are
controlling winding currents only The currents through the winding are 1root 3 (58) of the
current in the line
There are two contactors that are close during run often referred to as the main contractor and
the delta contactor These are AC3 rated at 58 of the current rating of the motor The third
contactor is the star contactor and that only carries star current while the motor is connected in star
The current in star is one third of the current in delta so this contactor can be AC3 rated at one
third (33) of the motor rating
Star-delta Starter Consists following units
1) Contactors (Main star and delta contactors) 3 Norsquos (For Open State Starter) or 4 Norsquos (Close
Transient Starter)
2) Time relay (pull-in delayed) 1 No
3) Three-pole thermal over current release 1No
4) Fuse elements or automatic cut-outs for the main circuit 3 Nos
5) Fuse element or automatic cut-out for the control circuit 1No
Power Circuit of Star Delta Starter
1 The main circuit breaker serves as the main power supply switch that supplies electricity to the
power circuit
2 The main contactor connects the reference source voltage R Y B to the primary terminal of the
motor U1 V1 W1
21 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
3 In operation the Main Contactor (KM3) and the Star Contactor (KM1) are closed initially and
then after a period of time the star contactor is opened and then the delta contactor (KM2) is
closed The control of the contactors is by the timer (K1T) built into the starter The Star and Delta
are electrically interlocked and preferably mechanically interlocked as well In effect there are
four states
4 The star contactor serves to initially short the secondary terminal of the motor U2 V2 W2 for the
start sequence during the initial run of the motor from standstill This provides one third of DOL
current to the motor thus reducing the high inrush current inherent with large capacity motors at
startup
5 Controlling the interchanging star connection and delta connection of an AC induction motor is
achieved by means of a star delta or wye delta control circuit The control circuit consists of push
button switches auxiliary contacts and a timer
Control Circuit of Star-Delta Starter (Open Transition)
1 The ON push button starts the circuit by initially energizing Star Contactor Coil (KM1) of star
circuit and Timer Coil (KT) circuit
2 When Star Contactor Coil (KM1) energized Star Main and Auxiliary contactor change its
position from NO to NC
3 When Star Auxiliary Contactor (1)( which is placed on Main Contactor coil circuit )became
NO to NC itrsquos complete The Circuit of Main contactor Coil (KM3) so Main Contactor Coil
energized and Main Contactorrsquos Main and Auxiliary Contactor Change its Position from NO
To NC This sequence happens in a friction of time
4 After pushing the ON push button switch the auxiliary contact of the main contactor coil (2)
which is connected in parallel across the ON push button will become NO to NC thereby
providing a latch to hold the main contactor coil activated which eventually maintains the
control circuit active even after releasing the ON push button switch
5 When Star Main Contactor (KM1) close its connect Motor connects on STAR and itrsquos
connected in STAR until Time Delay Auxiliary contact KT (3) become NC to NO
6 Once the time delay is reached its specified Time the timerrsquos auxiliary contacts (KT)(3) in
Star Coil circuit will change its position from NC to NO and at the Same Time Auxiliary
contactor (KT) in Delta Coil Circuit(4) change its Position from NO To NC so Delta coil
energized and Delta Main Contactor becomes NO To NC Now Motor terminal connection
change from star to delta connection
7 A normally close auxiliary contact from both star and delta contactors (5amp6)are also placed
opposite of both star and delta contactor coils these interlock contacts serves as safety
switches to prevent simultaneous activation of both star and delta contactor coils so that one
22 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
cannot be activated without the other deactivated first Thus the delta contactor coil cannot be
active when the star contactor coil is active and similarly the star contactor coil cannot also
be active while the delta contactor coil is active
8 The control circuit above also provides two interrupting contacts to shutdown the motor
The OFF push button switch break the control circuit and the motor when necessary The
thermal overload contact is a protective device which automatically opens the STOP Control
circuit in case when motor overload current is detected by the thermal overload relay this is to
prevent burning of the motor in case of excessive load beyond the rated capacity of the motor
is detected by the thermal overload relay
9 At some point during starting it is necessary to change from a star connected winding to a
delta connected winding Power and control circuits can be arranged to this in one of two
ways ndash open transition or closed transition
What is Open or Closed Transition Starting
(1) Open Transition Starters
Discuss mention above is called open transition switching because there is an open state between
the star state and the delta state
In open transition the power is disconnected from the motor while the winding are reconfigured via
external switching
When a motor is driven by the supply either at full speed or at part speed there is a rotating
magnetic field in the stator This field is rotating at line frequency The flux from the stator field
induces a current in the rotor and this in turn results in a rotor magnetic field
When the motor is disconnected from the supply (open transition) there is a spinning rotor within
the stator and the rotor has a magnetic field Due to the low impedance of the rotor circuit the time
constant is quite long and the action of the spinning rotor field within the stator is that of a
generator which generates voltage at a frequency determined by the speed of the rotor When the
motor is reconnected to the supply it is reclosing onto an unsynchronized generator and this result
in a very high current and torque transient The magnitude of the transient is dependent on the
phase relationship between the generated voltage and the line voltage at the point of closure can
be much higher than DOL current and torque and can result in electrical and mechanical damage
Open transition starting is the easiest to implement in terms or cost and circuitry and if the timing
of the changeover is good this method can work well In practice though it is difficult to set the
necessary timing to operate correctly and disconnectionreconnection of the supply can cause
significant voltagecurrent transients
In Open transition there are Four states
23 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 OFF State All Contactors are open
2 Star State The Main [KM3] and the Star [KM1] contactors are closed and the delta [KM2]
contactor is open The motor is connected in star and will produce one third of DOL torque at one
third of DOL current
3 Open State This type of operation is called open transition switching because there is an
open state between the star state and the delta state The Main contractor is closed and the Delta
and Star contactors are open There is voltage on one end of the motor windings but the other end
is open so no current can flow The motor has a spinning rotor and behaves like a generator
4 Delta State The Main and the Delta contactors are closed The Star contactor is open The
motor is connected to full line voltage and full power and torque are available
(2) Closed Transition StarDelta Starter
There is a technique to reduce the magnitude of the switching transients This requires the use of a
fourth contactor and a set of three resistors The resistors must be sized such that considerable
current is able to flow in the motor windings while they are in circuit
The auxiliary contactor and resistors are connected across the delta contactor In operation just
before the star contactor opens the auxiliary contactor closes resulting in current flow via the
resistors into the star connection Once the star contactor opens current is able to flow round
through the motor windings to the supply via the resistors These resistors are then shorted by the
delta contactor If the resistance of the resistors is too high they will not swamp the voltage
generated by the motor and will serve no purpose
In closed transition the power is maintained to the motor at all time This is achieved by
introducing resistors to take up the current flow during the winding changeover A fourth
contractor is required to place the resistor in circuit before opening the star contactor and then
removing the resistors once the delta contactor is closed These resistors need to be sized to carry
the motor current In addition to requiring more switching devices the control circuit is more
complicated due to the need to carry out resistor switching
In Close transition there are Four states
1 OFF State All Contactors are open
2 Star State The Main [KM3] and the Star [KM1] contactors are closed and the delta [KM2]
contactor is open The motor is connected in star and will produce one third of DOL torque at one
third of DOL current
Star Transition State The motor is connected in star and the resistors are connected across the
delta contactor via the aux [KM4] contactor
24 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Closed Transition State The Main [KM3] contactor is closed and the Delta [KM2] and Star
[KM1] contactors are open Current flows through the motor windings and the transition resistors
via KM4
Delta State The Main and the Delta contactors are closed The transition resistors are shorted out
The Star contactor is open The motor is connected to full line voltage and full power and torque
are available
Effect of Transient in Starter (Open Transient starter)
It is Important the pause between star contactor switch off and Delta contactor switch is on correct
This is because Star contactor must be reliably disconnected before Delta contactor is activated It
is also important that the switch over pause is not too long
For 415v Star Connection voltage is effectively reduced to 58 or 240v The equivalent of 33
that is obtained with Direct Online (DOL) starting
If Star connection has sufficient torque to run up to 75 or 80 of full load speed then the motor
can be connected in Delta mode
When connected to Delta configuration the phase voltage increases by a ratio of V3 or 173 The
phase currents increase by the same ratio The line current increases three times its value in star
connection
During transition period of switchover the motor must be free running with little deceleration
While this is happening ldquoCoastingrdquo it may generate a voltage of its own and on connection to the
supply this voltage can randomly add to or subtract from the applied line voltage This is known as
transient current Only lasting a few milliseconds it causes voltage surges and spikes Known as
a changeover transient
Size of each part of Star-Delta starter
(1) Size of Over Load Relay
For a star-delta starter there is a possibility to place the overload protection in two positions in the
line or in the windings
Overload Relay in Line
In the line is the same as just putting the overload before the motor as with a DOL starter
The rating of Overload (In Line) = FLC of Motor
Disadvantage If the overload is set to FLC then it is not protecting the motor while it is in delta
(setting is x1732 too high)
Overload Relay in Winding
25 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
In the windings means that the overload is placed after the point where the wiring to the contactors
are split into main and delta The overload then always measures the current inside the windings
The setting of Overload Relay (In Winding) =058 X FLC (line current)
Disadvantage We must use separate short circuit and overload protections
(2) Size of Main and Delta Contractor
1 There are two contactors that are close during run often referred to as the main contractor and
the delta contactor These are AC3 rated at 58 of the current rating of the motor
Size of Main Contactor= IFL x 058
(3) Size of Star Contractor
The third contactor is the star contactor and that only carries star current while the motor is
connected in star The current in star is 1 radic3= (58) of the current in delta so this contactor can
be AC3 rated at one third (33) of the motor rating
Size of Star Contactor= IFL x 033
Motor Starting Characteristics of Star-Delta Starter
Available starting current 33 Full Load Current
Peak starting current 13 to 26 Full Load Current
Peak starting torque 33 Full Load Torque
Advantages of Star-Delta starter
The operation of the star-delta method is simple and rugged
It is relatively cheap compared to other reduced voltage methods
Good TorqueCurrent Performance
It draws 2 times starting current of the full load ampere of the motor connected
Disadvantages of Star-Delta starter
Low Starting Torque (Torque = (Square of Voltage) is also reduce)
Break In Supply ndash Possible Transients
Six Terminal Motor Required (Delta Connected)
It requires 2 set of cables from starter to motor
It provides only 33 starting torque and if the load connected to the subject motor requires higher
starting torque at the time of starting than very heavy transients and stresses are produced while
changing from star to delta connections and because of these transients and stresses many
electrical and mechanical break-down occurs
26 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
In this method of starting initially motor is connected in star and then after change over the motor
is connected in delta The delta of motor is formed in starter and not on motor terminals
High transmission and current peaks When starting up pumps and fans for example the load
torque is low at the beginning of the start and increases with the square of the speed When
reaching approx 80-85 of the motor rated speed the load torque is equal to the motor torque and
the acceleration ceases To reach the rated speed a switch over to delta position is necessary and
this will very often result in high transmission and current peaks In some cases the current peak
can reach a value that is even bigger than for a DOL start
Applications with a load torque higher than 50 of the motor rated torque will not be able to start
using the start-delta starter
Low Starting Torque The star-delta (wye-delta) starting method controls whether the lead
connections from the motor are configured in a star or delta electrical connection The initial
connection should be in the star pattern that results in a reduction of the line voltage by a factor of
1radic3 (577) to the motor and the current is reduced to 13 of the current at full voltage but the
starting torque is also reduced 13 to 15 of the DOL starting torque
The transition from star to delta transition usually occurs once nominal speed is reached but is
sometimes performed as low as 50 of nominal speed which make transient Sparks
Features of star-delta starting
1 For low- to high-power three-phase motors
2 Reduced starting current
3 Six connection cables
4 Reduced starting torque
5 Current peak on changeover from star to delta
6 Mechanical load on changeover from star to delta
Application of Star-Delta Starter
The star-delta method is usually only applied to low to medium voltage and light starting
Torque motors
The received starting current is about 30 of the starting current during direct on line start and the
starting torque is reduced to about 25 of the torque available at a DOL start This starting
method only works when the application is light loaded during the start If the motor is too heavily
27 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
loaded there will not be enough torque to accelerate the motor up to speed before switching over
to the delta position
LESSON 1 WIRING SYSTEM OF SINGLE PHASE DISTRIBUTION BOARD
Introduction
28 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
29 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
30 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
31 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 2 WIRING SYSTEM OF SINGLE PHASE LIGHTING CIRCUIT Introduction
Objectives
1 Identify component and the specification
2 Wire component according to the schematic diagram
3 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Wiring bay Perforated metal 180 cm x 180 cm 1
2 Cut out fuse 63 A 240 V 1
3 Neutral link 1
4 Single pole one way switch cw
switch box
5A 240Vac 4
5 single pole two way switch cw
switch box
5A 240Vac 2
6 RCCB In = 40 A Tripping current
100mA240 Vac 50 Hz
1
7 Main switch 32 A 240V 1
8 kWatthour meter 40 A 240 Vac 1
9 Single pole MCB 6A 240 Vac 1
10 Self tapping Wood screw As required
11 DIN rail 35 mm width As required
32 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
12 PVC trunking 50 mm x 50 mm As required
13 Terminal blocks 5 A As required
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
1 One way switch to control one lamp
2 One way switch to control two lamps
3 Two of two way switch to control one lamp
4 Two of single pole two way switch and one of an intermediate switch to control one
lamp
5 One unit of ceiling fan and fan regulator to be controlled by one way switch
4 Test the functionality of completed project
LESSON 3ndash WIRING SYSTEM OF SINGLE PHASE POWER CIRCUIT Introduction
33 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
34 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify types of component and its specification
2 Wire component according to the schematic diagram given
3 Test the functionality of the circuit dead circuit test life circuit test
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board Perforated Metal 1
2 kWh meter 240 V 40 A 1
3 Socket outlet 13A 240Vac 4
4 RCCB 40A Trip Amps
30mA240 Vac
1
5 3 pin socket 240Vac 13A 4
6 Single pole MCB 20A 240 V 2
7 DOL starter 1 kW 240Vac 2
8 1 phase induction motor 2Hp 240 Vac 1
9 Cooker control unit 4kW 240Vac 1
10 Water heater point 4kW 240 Vac 1
11 DIN rail 35 mm As required
12 PVC casing 20mm As required
13 Flexible wires 05 mm As required
14 Terminal block 10 A As required
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Wire two unit of 13 A socket outlet in radial circuit
3 Wire four units of 13 A socket outlet in ring circuit
4 Wire one unit DOL starter for air-conditioner point
5 Wire one unit of cooker control unit point
6 Wire one unit of water heater point
7 Test the functionality of each component by using mmeter or power supply whichever
applicable
8 Wire component according to circuit diagram
9 Test the functionality of completed project dead circuit test life circuit test
Note
35 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Ensure that the correct rating of protection device and size of wire used
LESSON 4ndash CONDUIT BENDING AND TRUNKING FABRICATION TECHNIQUE
Common fitting used in an industrial wiring
Cutting and threading the condute
36 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
37 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
38 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify conduit fitting and the specification
2 Measure and Cut steel conduit according to specified dimension
3 Bend and fabricate conduit at 45 90 according to layout diagram
4 Wire component according to the schematic diagram
5 Test the functionality of the circuit
39 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Conduit Bender Oslash 19 mm ( frac34 ldquo) 1
2 Measuring Tape 3 metre 1
3 Hacksaw frame and blade 30cm 1
4 Conduit cutter 1
5 Pipe Vise 1
6 Pipe Wrench 1
7 Ratchet Dies 20 mm 1
8 Metal trunking 50 mm x 50 mm 1
9 GI conduit 20mm 1
10 End box 20 mm 1
11 Flexible wires 05 mm As required
12 Connectors 5 A As required
13 Single core PVC ins Cable 25 mm 2 As required
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Wire two unit of 13 A socket outlet in radial circuit
3 Wire four unit of 13 A socket outlet in ring circuit
4 Wire one unit DOL starter for air-conditioner point
5 Wire one unit of cooker control unit point
6 Wire one unit of water heater point
7 Test the functionality of each component by using multimeter or power supply whichever
applicable
8 Wire component according to circuit diagram
9 Test the functionality of completed project
Note
Ensure that the rating of protection device and size of wire
K prior to 31 March
2004 (BS 7671)
(formerly)
bare conductor
sleeved at terminations (formerly)
40 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 5 ndashWIRING SYSTEM OF 1 Oslash LIGHTING AND POWER CIRCUIT
POWER CIRCUITSa Radial circuits
Radial circuits are arranged in the same way as item 1 above in lighting layouts in that each socket
outlet is supplied via the previous one
Points to note
1 The number of socket outlets complying with BS 1363 is unlimited for a floor area of up to 50m 2 if
the circuit protection is a 30 A or 32 A cartridge fuse or circuit breaker the cable being 4 mm PVC
copper or 25 mm2 mineral insulated (mi)
2 The number of socket outlets is unlimited for a floor area up to 20 m 2 with any type of circuit
protection of 20 A using 25 mm2 PVC copper cable or 15 mm2 mi
3 The total number of fused spurs is unlimited
b ring final circuits
These circuits are the same as radial circuits except that the final socket outlet is wired back to the
supply position In effect any outlet is supplied from two directions (Fig 152)
Points to note
1 Every twin-socket outlet counts as two single-socket outlets
2 The number of non-fused spurs must not exceed the total number of points on the ring Fig 158
shows seven points on the ring and five spurs
3 The fuse rating of a fused spur box must not exceed 13 A and the current rating of all points supplied
by the fused spur must not exceed 13 A
4 Non-fused spurs must supply no more than one single or one double socket on the ring Fig 158
shows seven points on the ring and five spurs rating of all points supplied by the fused spur must not
exceed 13 A or one stationary appliance
CapacityMain conductor size
copper (mm2)
Earth conductor
size (mm2)
Circuit breaker
capacity (A)
Up to 600 W 15 15 6
600ndash1200 W 1525 15 10
1200ndash1800 W 254 25 16
41 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Ring circuit
(floor area 100 m2)25 15 3032
A2 radial circuit
(floor area 75 m2)40 25 3032
A3 radial circuit
(floor area 50 m2)25 15 20
Air conditioner (15 tonne) 60 60 3032
Cooker 60 60 3032
Water heater 40 40 20
Objectives
1 Identify component and the specification
2 Wire component according to the schematic diagram
3 Test the functionality of the circuit
42 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board Perforated 1
2 Cut out fuse and neutral link 60A 240V 1each
3 kWh meter 240V 40A 1
4 Switched Socket outlet 13A 240Vac 4
5 Single pole two way switch cw switch
box
5A 240Vac 2
6 RCCB ELCB 63 A Tripping current 100mA
415 Vac
1
7 3 pin plug 240Vac 13A 4
8 Single pole MCB 20 A 2
9 Single pole MCB 6A 1
10 Single pole MCB 20A 2
11 DOL starter 240Vac 2
12 1 phase induction motor 2hp 240 Vac 1
13 Self tapping Wood screw As required
14 DIN rail Stainless steel allum35 mm As required
15 PVC pipe 20mm dia As required
16 End box 20 mm dia 4
17 Flexible wires 05 mm 2 As required
18 Connectors 5 A As required
Procedures
43 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
4 Test the functionality of completed project
LESSON 6 ndash WIRING SYSTEM OF 3 Oslash DISTRIBUTION BOARD
Introduction
44 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
45 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
46 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
47 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
48 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify each component and the specification
2 Wire component according to the schematic diagram given
3 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting Board 450 x 600 mm Perforated metal 1
2 5 pin round socket and plug 415V ac 32A 1
3 Cut out fuse 60 A 3
4 Neutral link 1
5 kWatt hour meter 415V 60A 1
6 ELCB RCCB 3P+N In=63A415 Vac I trip= 300mA 1
7 ELCB RCCB 3P+N In=63A415 Vac I trip= 30mA 1
8 Single pole MCB 6A 240 V 3
9 Single pole MCB 20A 240 V 3
10 DOL starter 20 A 240Vac 2
11 Socket outlet 15 A 240 Vac 1
12 Switched Socket outlet 13 A 240 Vac 3
13 Led indicating light 5A 240 Vac 3
14 Single pole 4 gang 1 way switch 5A 240 Vac 2
15 Single pole 2 way switch 5A 240 Vac 2
16 1 phase induction motor 1 kW 240Vac 1
17 Metal trunking 30 mm x30 mm As required
18 Self tapping Wood screw 4 mm x 20 mm As required
19 DIN rail 25 mm x 1mm
20 GI steel rigid conduit 20mm As required
21 Flexible conduit 20mm As required
22 End box 20 mm 4
23 Flexible wires 05 mm 2 As required
24 Single core PVC insulated wire 15 mm 2 As required
25 Single core PVC insulated wires 25 mm 2 As required
26 Terminal block 10 A As required
Procedures
49 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify each components and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
4 Test the functionality of completed project
1 dead circuit test
2 life circuit
Note Proper earthing should be made
50 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 7 ndash WIRING SYSTEM OF THREE PHASE LIGHTING AND POWER CIRCUIT
51 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
52 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify component and the specification
2 Wire component according to the schematic diagram
3 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting bay Board Perforated metal 180 cm x 180 cm 1
2 k Watt hour meter 415V 60A 1
3 MCCB 415V 60A
4 ELCB RCCB In=60A415 Vac I trip=30mA 1
5 5 pin round Socket and
plug
415Vac 32A 4
6 Single pole MCB 6A 1
7 Triple pole MCB 20A 2
8 Triple pole Main switch 60A 1
9 DOL starter 240Vac 2
10 3 phase induction motor 2hp 415 Vac 1
11 1 phase induction motor 1
12 Metal trunking 30 mm x30 mm As required
13 Self tapping Wood screw 4 mm x 20 mm As required
14 DIN rail 25 mm x 1mm
15 GI steel rigid conduit 20mm As required
16 Flexible conduit 20mm As required
17 End box 20 mm 4
18 Flexible wires 05 mm As required
19 Connectors 10 A As required
Procedures
1 Identify each components and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
4 Test the functionality of completed project
1 dead circuit 2 life circuit test
5 Record the current drawn by the load as connected in star and delta
Note Proper earthing should be made
53 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 8 INSPECTION AND TESTING OF ELECTRICAL INSTALLATION
On completion of a wiring installation a number of tests on the installation have to be conducted to
ascertain that the wiring circuits and connected appliances are safe for use Prior to carrying out the
tests an inspection has to be done The results of the inspectionsupervision and test have to be
presented in Form G (as in Appendix IV) and Form H (as in Appendix V)
To have the test certification as in Form H the following tests shall be conducted
i Continuity Test
ii Insulation Resistance Test
iii Polarity Test
iv Earth Electrode Resistance test and
v Residual Current Device Test
1 Continuity Test
There are 3 main types of continuity tests for the final circuits-
i Protection Conductor Continuity Test
ii Final Ring Circuit Conductor Continuity Test
iii Live and Neutral Conductor Continuity Test
a) Protection Conductor Continuity Test
bull To ascertain that all protection conductors are connected in the correct and effective manner
bull Test equipment ndash Multimeter (Ohm range) or Ohm meter
54 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
bull Test Method
1 1048766 Ensure that the main switch RCD and MCB are open circuited (switched off) and all loads
are disconnected
2 1048766 Connected the test leads as in the Figure 81 The meter reading shall be less than 1 Ω
55 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Final Ring Circuit Conductor Continuity Test
bull To ensure that all conductors around the ring circuit have continuity
bull Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
bull Test Method
1 1048766 Disconnect both the supply source live conductors from the MCB the neutral conductor
from the neutral terminals and the earth conductor from the earth terminal in the distribution
fuse box
2 1048766 Connect the test leads as in the Figure 82 (EE)
3 1048766 Repeat the procedure for (L-L) and (N-N)
4 1048766 The meter reading value shall be less than 1 ohm
56 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Live and Neutral Conductor Continuity Test
a To ensure that each conductor in the circuit has continuity
b Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
2 Test Method
1 1048766 Switch off the Main switch RCD and MCB
2 1048766 Disconnect all loads
3 1048766 Switch on all switches in the circuit
4 1048766 Disconnect the fusesfinal circuit breakers and close the circuit
5 1048766 Carry out the test as shown in Figure 83
6 1048766 The meter reading value shall be less than 1Ω
57 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
58 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
CONTINUITY TEST
Insulation Resistance Test
i Ensure that there is no leakage current between phase conductors phase and neutral conductors and
phase conductor and earth
ii Test the strength of the cable insulation
iii Test Equipment ndash Insulation Resistance Tester operating voltage is 250VDC or 500VDC
iv Test Method
1 1048766 Switch off main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
59 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
4 1048766 Carry out test as in the Table below
5 1048766 Meter reading value shall be less than 1 Megaohm
60 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
61 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Insulation resitance test
62 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
INSULATION RESISTANCE TEST BETWEEN CONDUCTORS AND OPPOSITE POLARITY
Polarity Testi Ensure that each fuse or single pole control and protection device is connected only in the phase
conductor
ii Intermediate contact of Edison screw lamp holder is connected to the phase conductor
iii Ensure that phase neutral and earth conductors at socket outlets are connected at the correct
terminals
iv Test Equipment ndash Multimeter (Ohm range) or Ohm meter
v Test Method
1 1048766 Switch off Main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in Figure 85
63 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
5 1048766 Test switches and single phase control devices at the phase conductors
6 1048766 Test socket outlet connection sources
7 1048766 Test Edison screw lamp holder connections
8 1048766 Meter reading value shall be less than 1 Ω
64 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Polarity test
65 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Earth Electrode Resistance Testi To test the earth electrode resistance
ii To ascertain the suitability of the location of the electrode
iii To ensure that the electrode is not buried within the resistance area of another electrode
iv Test equipment ndash Earth Resistance Tester
v Test method -
1 1048766 Terminal rsquoErsquo is connected to the electrode to be tested (green conductor)
2 1048766 Terminal lsquoPrsquo is connected to the potential spike (yellow conductor) at a distance of 10
meters from the earth electrode
3 1048766 Terminal lsquoCrsquo is connected to the current spike (red conductor) at a distance of 20 meters
from the earth electrode
Earth Electrode Resistance Measurement Method (Figure 86)
This test must be repeated at least three times to ensure that the reading is not affected by interacting
earthing regions
i Record the first reading (Z1) Example Z1 = 10 Ω
ii Move the voltage spike to a distance of 6 meters from the original position Record the second
reading (Z2 ) Example Z2 = 10 Ω
iii Move the voltage spike to a distance of 6 meters from the original position Record the third
reading (Z3) Example Z3 = 10 Ω
66 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Residual Current Device Testi Ensure that the residual current device (RCD) trips within the set time on the occurrence of current
leakage to earth
ii Test Equipment ndash RCD Tester RCCB Tester
iii Test Method 1
1 1048766 Use the Trip Test Button
2 1048766 Press the trip button found on the RCD to determine if it trips or otherwise This test would
not be able to determine the sensitivity of the RCD nor the time taken for it to trip
iv Test Method 2
i 1048766 Use a RCD Tester
ii This equipment is equipped with a 13A plug which can be connected to a 13A socket outlet
Select the RCD sensitivity to be the same as the sensitivity of the RCD to be tested to
determine if the RCD can trip The time to trip shall not exceed 40 mS
iii 1048766 Test method ndash
a) Position the selection switch in accordance with the sensitivity of the RCD used
Example 100 mA 01 A
b) Position the operations switch to lsquoNo Triprsquo (frac12 Rated mA = 50) connect the 3 pin plug to
the 13A socket outlet
67 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
c) Switch on the 13A socket outlet ndash ensure that the P-N and P-E lights light up
This shows that the polarity is correct (Note if both the lights as above do not light up the test cannot
be continued)
d) Press the test button ndash the reading shows less than 200 mS and simultaneously the lsquotestrsquo light lights
up and the P-N and P-E lights do not light up At that instant the RCD will not trip
e) Move the selection switch to 180o (+ve wave) ndash repeat steps (d) and (e) Move the operations
switch to lsquoTriprsquo (Rated mA = 100)
g) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200mS
h) Move the selection switch to 0o (-ve wave)
i) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
j) The above test is repeated until a near correct reading is obtained
k) Record the test results
l) Change the operations switch to lsquoFast Triprsquo and press the test button ndash RCD will trip within a
time not exceeding 40 millisecond
m) Repeat a number of times at 0o or 180o
On completion of a wiring installation a number of tests on the installation have to be conducted to
ascertain that the wiring circuits and connected appliances are safe for use Prior to carrying out the
tests an inspection has to be done the following tests shall be conducted
i Continuity Test
ii Insulation Resistance Test
iii Polarity Test
iv Earth Electrode Resistance test and
v Residual Current Device Test
821 Continuity Test
There are 3 main types of continuity tests for the final circuits-
i Protection Conductor Continuity Test
ii Final Ring Circuit Conductor Continuity Test
68 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
iii Live and Neutral Conductor Continuity Test
a) Protection Conductor Continuity Test
bull To ascertain that all protection conductors are connected in the correct and effective manner
bull Test equipment ndash Multimeter (Ohm range) or Ohm meter
bull Test Method
1 1048766 Ensure that the main switch RCD and MCB are open circuited (switched off) and all loads are
disconnected
2 1048766 Connected the test leads as in the Figure 81
3 1048766 The meter reading shall be less than 1 Ω
Final Ring Circuit Conductor Continuity Test
bull To ensure that all conductors around the ring circuit have continuity
bull Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
bull Test Method
1 1048766 Disconnect both the supply source live conductors from the MCB the neutral conductor
from the neutral terminals and the earth conductor from the earth terminal in the distribution
fuse box
2 1048766 Connect the test leads as in the Figure 82 (EE)
3 1048766 Repeat the procedure for (L-L) and (N-N)
4 1048766 The meter reading value shall be less than 1 ohm Figure 82 - Final Ring Circuit Conductor
Continuity Test Ohm Meter
Disconnect both the supply source cables from mcbfuse
Take readings at earth conductors of both sources and note resistance readings
Live and Neutral Conductor Continuity Test
1 To ensure that each conductor in the circuit has continuity
2 Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
3 Test Method
1 1048766 Switch off the Main switch RCD and MCB
2 1048766 Disconnect all loads
3 1048766 Switch on all switches in the circuit
4 1048766 Disconnect the fusesfinal circuit breakers and close the circuit
5 1048766 Carry out the test as shown in Figure 83
6 1048766 The meter reading value shall be less than 1 ohm Figure 83 - Live and Neutral
Conductor Continuity Test Ohm Meter
Insulation Resistance Test
69 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
i Ensure that there is no leakage current between phase conductors phase and neutral conductors and
phase conductor and earth
ii Test the strength of the cable insulation
iii Test Equipment ndash Insulation Resistance Tester Operating voltage is 250VDC or 500VDC
iv Test Method
1 1048766 Switch off main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in the Table below
5 1048766 Meter reading value shall be less than 1 Megaohm
Polarity Test
i Ensure that each fuse or single pole control and protection device is connected only in the phase
conductor
ii Intermediate contact of Edison screw lamp holder is connected to the phase conductor
iii Ensure that phase neutral and earth conductors at socket outlets are connected at the correct
terminals
iv Test Equipment ndash Multimeter (Ohm range) or Ohm meter
v Test Method
1 1048766 Switch off Main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in Figure 85
5 1048766 Test switches and single phase control devices at the phase conductors
6 1048766 Test socket outlet connection sources
7 1048766 Test Edison screw lamp holder connections
8 1048766 Meter reading value shall be less than 1 Ω
Earth Electrode Resistance Test
i To test the earth electrode resistance
70 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
ii To ascertain the suitability of the location of the electrode
iii To ensure that the electrode is not buried within the resistance area of another electrode
iv Test equipment ndash Earth Resistance Tester
v Test method -
1 1048766 Terminal rsquoErsquo is connected to the electrode to be tested (green conductor)
2 1048766 Terminal lsquoPrsquo is connected to the potential spike (yellow conductor) at a distance of 10
meters from the earth electrode
3 1048766 Terminal lsquoCrsquo is connected to the current spike (red conductor) at a distance of 20 meters
from the earth electrode E P C Electrode 10 meter 10 meter
Figure 86 ndash Earth Electrode Resistance Measurement Test Equipment
Earth Electrode Resistance Measurement Method (Figure 86)
This test must be repeated at least three times to ensure that the reading is not affected by interacting
earthing regions
i Record the first reading (Z1) Example Z1 = 10 Ω
ii Move the voltage spike to a distance of 6 meters from the original position Record the second
reading (Z2) Example Z2 = 10 Ω
iii Move the voltage spike to a distance of 6 meters from the original position Record the third
reading (Z3)
Example Z3 = 10 Ω
Residual Current Device Test
71 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
i Ensure that the residual current device (RCD) trips within the set time on the occurrence of current
leakage to earth
ii Test Equipment ndash RCD Tester RCCB Tester
iii Test Method 1
1 1048766 Use the Trip Test Button
2 1048766 Press the trip button found on the RCD to determine if it trips or otherwise This test would
not be able to determine the sensitivity of the RCD nor the time taken for it to trip
iv Test Method 2
1048766 Use a RCD Tester
This equipment is equipped with a 13A plug which can be connected to a 13A socket outlet Select the
RCD sensitivity to be the same as the sensitivity of the RCD to be tested to determine if the RCD can
trip The time to trip shall not exceed 40 mS
1048766 Test method ndash
a) Position the selection switch in accordance with the sensitivity of the RCD used
Example 100 mA 01 A
b) Position the operations switch to lsquoNo Triprsquo (frac12 Rated mA = 50) connect the 3 pin plug to
the 13A socket outlet
c) Switch on the 13A socket outlet ndash ensure that the P-N and P-E lights light up This shows that
the polarity is correct (Note if both the lights as above do not light up the test cannot be
continued)
d) Press the test button ndash the reading shows less than 200 millisecond and simultaneously the
lsquotestrsquo light lights up and the P-N and P-E lights do not light up At that instant the RCD will
not trip
e) Move the selection switch to 180o (+ve wave) ndash repeat steps (d) and (e) = 100)
f) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
g) Move the selection switch to 0o (-ve wave)
h) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
i) The above test is repeated until a near correct reading is obtained
j) Record the test results
k) Change the operations switch to lsquoFast Triprsquo and press the test button ndash RCD will trip within a
time not exceeding 40 mS
l) Repeat a number of times at 0o or 180o
72 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 9 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (DC)
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
73 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Start stop button 240Vac 5A 2
9 Filament lamp (Bulb ) 240Vac 40W 3
10 Overload Relay 415V 20A 3
11 Three phase induction motor 5 hp 3
12 Single phase step down transformer 2500VA 1
13 Single core PVC insulated Cable 1mm 2 As required
14 Single core PVC insulated Cable 25mm 2 As required
15 DIN rail 35 mm As required
16 PVC type Cable tray 50 mm x 50 mm As required
17 Cable ties 4 ldquo As required
18 Flexible wires 05 mm As required
19 PVC Connectors 5 A amp 20 A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the schematic
diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a optional exercise
i Simple DOL starter
ii Forward reverse DOL starter
iii Forward Reverse Dahlander motor
iv Three motors operated in sequence by DOL starter operated by manual push
button or time delay relay
74 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
a One loop per-cycle
b Continuous operation in a loop
c optional circuit design to represent the same task
v Only one out of three motors to be operated at a time (quiz)
4 Test the functionality of completed project
LESSON 10 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (AC)
75 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 1
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Lamp point 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
76 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
11 Overload Relay 415V 20A 3
12 Three phase induction
motor
5 hp 3
13 Single core PVC insulated
Cable
1mm 2 As required
14 Single core PVC insulated
Cable
25mm 2 As required
15 DIN rail 35 mm As required
16 PVC type Cable tray 50 mm x 50 mm As required
17 Cable ties 4 ldquo As required
18 Flexible wires 05 mm As required
19 PVC Connectors 5 A amp 20 A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the
schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram optional exercise
4 Simple DOL starter
5 Forward reverse DOL starter
6 Test the functionality of completed project
77 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 1
78 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
cm
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Indicating light 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
11 Overload Relay 415V 20A 3
12 Three phase induction motor 5 hp 3
13 Single phase step down
transformer
2500VA 1
14 Single core PVC insulated
Cable
1mm 2 As required
15 Single core PVC insulated
Cable
25mm 2 As required
16 DIN rail 35 mm As required
17 PVC type Cable tray 50 mm x 50 mm As required
18 Cable ties 4 ldquo As required
19 Flexible wires 05 mm As required
20 PVC Connectors 5 A amp 20 A 240 V As required
21 Single pole MCB 6A 240 V 1
22 Single pole MCB 2A 240 V 1
23 Triple pole MCB 20A 415 V 1
24 Mounting board 30 cm x 40 cm x 3
cm
1
25 Relay cw 11 pin socket 10 A 240 Vac 2
26 Time delay relay 10 A 240 Vac 3
27 Triple pole Contactor 20A 240Vac 3
28 Batten type Lamp holder 240Vac 10 A 3
29 Start stop button 240Vac 10A 2
30 Indicating light (Bulb ) 240Vac 25W 3
31 Overload Relay 415V 20A 1
32 Three phase dahlander type
induction motor
5 hp 1
33 Single phase step down
transformer
24024Vac
2500VA
1
79 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
34 Single core PVC insulated
Cable
1mm 2 As required
35 Single core PVC insulated
Cable
25mm 2 As required
36 DIN rail 35 mm As required
37 PVC type Cable tray 50 mm x 50 mm As required
38 Cable ties 4 ldquo As required
39 Flexible wires 075 mm As required
40 PVC Connectors 5 A amp 20 A 240 V As required
41 Terminal block 20A 240Vac As required
Procedures
5 Identify each component according to specification and quantity required from the schematic
diagram attached
6 Test the functionality of each component by using multi-meter or power supply whichever
applicable
7 Wire component according to circuit diagram
8 Three motors operated in sequence by DOL starter operated by manual push button or time
delay relay
a One loop per-cycle
b Continuous operation in a loop
c optional circuit design to represent the same task
d Only one out of three motors to be operated at a time (quiz)
9 Test the functionality of completed project
80 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
BASIC DESIGN INDUSTRIAL MOTOR CONTROL (SEQUENCE CONTROL)
THREE PHASE INDUCTION MOTOR OPERATED IN SEQUENCE BY DIRECT ON LINE
STARTER
LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
81 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
82 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Lcd lamp indicator 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
11 Overload Relay 415V 20A 3
12 Three phase induction motor 5 hp 3
13 Single phase step down transformer 2500VA 1
14 Single core PVC insulated Cable 1mm 2 As required
15 Single core PVC insulated Cable 25mm 2 As required
16 DIN rail 35 mm As required
17 PVC type Cable tray 50 mm x 50 mm As required
18 Cable ties 4 ldquo As required
19 Flexible wires 1 mm Oslash As required
20 PVC Terminal block 10A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the schematic
diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a optional exercise
i Forward Reverse dahlander motor
4 Test the functionality of completed project
83 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
THREE PHASE DAHLANDER TYPE INDUCTION MOTOR OPERATED FORWARD AND
REVERSE OPERATION BY DIRECT ON LINE STARTER
84 ndash 99EASYTECH ENTERPRISE
LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
Introduction
If a motors windings are connected in the star configuration any two phases will be in series across
the supply and hence the line current will be smaller(by 577) than if the windings were connected in
the delta arrangement
Hence larger-type motors with heavy starting currents are first connected in star and then when the
starting currents fall in delta This of course means that all six of the ends of the windings must be
brought to terminations outside the casing (Fig 833)
EZTECH
EZTECH ELECTRICAL INSTALLATION GUIDE
The automatic version of this starter incorporates a timing relay which automatically changes the
connections from star to delta Figs 834 and 835 show the wiring and schematic diagrams for a star
delta starter
Objectives
1 Identify component and the specification
2 Design forward reverse star delta starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
2 ndash 99EASYTECH ENTERPRISE
REV -C
LEGENDMCCB Moulded Case Circuit BreakerTOR Thermal Over Load RelayFOW-C Mains Forward ContactorREV-C Mains Reverse ContactorDC Delta ContactorSC Star ContactorS-SW Mains Selector Switch
SC
V2
W2
U2
DC
V1
W1
U1
TOR
TOR
FOW-C
30A MCCB
TOR
MAIN CIRCUIT FORWARD REVERSE STAR DELTA
RYBN S
-SW
3 PHASEINDUCTION MOTOR
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Relay 10 A 240V 3
5 Triple pole Contactor
6 cw NO NC auxiliary contact
240Vac 20 A 4
7 Overload Relay 415 V 1
8 LED indicator 240vac 5 A 4
9 Start stop button 240Vac 5A 2
10 DIN rail 35 mm As required
11 Flexible wires 1 mm As required
12 Single core PVC insulated
wire
25 mm As required
13 Terminal block 20 A As required
14 Squirrel cage motor 5kW 1
15 5 pin plug and socket 415V 20A 1
16 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
3 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
a Manual star delta
b Manual Forward reverse star delta starter
c Automatic star delta starter
d Automatic Forward reverse star delta starter
4 Test the functionality of completed project
4 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
Objectives
1 Identify component and the specification
2 Design auto transformer starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
5 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Autotransformer starter is used to start a 3 phase induction motor that has a rating between 10 to 15 hp
6 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Autotransformer set 10Kw 415 V 50 Hz 1
5 Triple pole Contactor 240Vac 4
6 Batten type Lamp holder 240 Vac 105 A 4
7 Start stop button 240Vac 10A 4
8 Filament lamp (Bulb ) 240Vac 40W 4
9 DIN rail 35 mm As required
10 Flexible wires 1 mm As required
7 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
11 Single core PVC insulated
wire
25 mm As required
12 Terminal block 20 A As required
13 Squirrel cage motor 10kW 1
14 5 pin plug and socket 415V 20A 1
15 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a open transient autotransformer starter
b close transient autotransformer starter
c Forward reverse autotransformer starter
4 Test the functionality of completed project
8 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
Objectives
1 Identify component and the specification
2 Design rotor resistance starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
9 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Rotor Resistor set 10kW 1
5 Triple pole Contactor 240Vac 20A 4
6 Indicating light 240vac 5 A 4
7 Start stop push button 240Vac 5A 4
8 DIN rail 35 mm As required
9 Flexible wires 1 mm 2 As required
10 Single core PVC insulated wire 25 mm 2 As required
11 Terminal block 20 A As required
12 Slip Ring motor 10kW 1
13 5 pin round 3 phase socket 415V 20A 1
14 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
10 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
4 Test the functionality of completed project
a Dead circuit test b Life circuit test
5 Measure starting and running Amps
LESSON 16
TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
An installation in general will suffer damage
Damage usually occurs on the electric motor control as follows
1 Damage to the main circuit
2 Damage to the control circuit
The cause of the damage
i Overcurrent overload short circuit
ii Leakage current to ground
iii Equipment malfunction
iv The main control circuit
a Trip of main circuit protection devices fire
b Defect of motor terminal such as short circuit fire loose
v The control circuit is not functioning -
a contactor relay relay time overload relay does not work damaged burned
b Loose cable connection disconnected
Detecting and Repairing Damage
Examples of damage are as follows
i Motor does not work
ii Motor function and overload relay trips
iii Motor function but only partially functional control circuit
Methods of detecting damage
Among the known methods necessary to detect damage are as follows
1 Turn off the electricity at the main switch (main switch) in order to avoid any danger during the
work carried out to detect damage
2 Check all the protective gear that controls the motor control main circuit
11 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
3 Make sure the damage function control circuit
4 Check the control circuit according to the schematic circuit diagram of the motor control
5 Check the operation of the control circuit
Note
Use wiring that has been installed on the SYSTEM OF MOTOR CONTROL BOARD by Forward
Reverse control circuit for Star Delta to test and look for damage
SELF-ASSESSMENT QUESTIONS
1 (a) Explain what is meant by the term lsquoback emfrsquo in a motor
(b) Outline the basic differences between series shunt and compound wound dc motors
2 (a) With the aid of diagrams explain how the speed of series shunt and compound-wound motors
may be controlled
(b) A 440V dc shunt-wound motor has a field resistance of 200R and an armature resistance of 06 R
When its speed is 20 rev d second the current drawn from the supply is 122A Calculate its back
emf at this speed If the speed were decreased to 19 revssecond the field flux remaining unchanged
calculate the new back emf and the new armature current
3 A load of 64 kW at 240 V is supplied from the terminals of a shunt-wound dc generator The field
resistance is 180 A Calculate the armature current
4 (a) Explain with the aid of a diagram how a rotating magnetic field may be
(b) What is meant by lsquosynchronous speedrsquo
Calculate the synchronous obtained speed of a 12 pole motor if the supply frequency is 50Hz
5 (a) Explain the action of a synchronous motor
(b) What methods are available to start a synchronous motor Explain with diagrams
6 (a) Explain the action of a cage induction motor
(b) What is meant by the term lsquosliprsquo
Calculate the percentage slip of a six pole induction motor running at 162 revssecond from a 50 Hz
supply
7 Describe with sketches three different ways of starting a single-phase induction motor
12 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
8 Explain with the aid of a sketch the action of a three-phase DOL starter
What are dashpots used for How are remote start and stop buttons connected
9 A I0 kW 240V 50Hz single-phase cage rotor induction motor is 85efficient and has a PF of 068
lagging Calculate the motor current and the value of capacitor required to raise the PF to 093
lagging
10 Calculate the torque developed by an 18 kW four-pole induction motor run at 35 slip from a
50Hz supply
APPENDIX 1
13 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 11
14 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 111
Attachment Reference
httpswwwtlc-directcoukBook621htm
httpwwwstgovmyindexphpms
15 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
3 In operation the Main Contactor (KM3) and the Star Contactor (KM1) are closed initially and
then after a period of time the star contactor is opened and then the delta contactor (KM2) is
closed The control of the contactors is by the timer (K1T) built into the starter The Star and Delta
are electrically interlocked and preferably mechanically interlocked as well In effect there are
four states
4 The star contactor serves to initially short the secondary terminal of the motor U2 V2 W2 for the
start sequence during the initial run of the motor from standstill This provides one third of DOL
current to the motor thus reducing the high inrush current inherent with large capacity motors at
startup
5 Controlling the interchanging star connection and delta connection of an AC induction motor is
achieved by means of a star delta or wye delta control circuit The control circuit consists of push
button switches auxiliary contacts and a timer
Control Circuit of Star-Delta Starter (Open Transition)
1 The ON push button starts the circuit by initially energizing Star Contactor Coil (KM1) of star
circuit and Timer Coil (KT) circuit
2 When Star Contactor Coil (KM1) energized Star Main and Auxiliary contactor change its
position from NO to NC
3 When Star Auxiliary Contactor (1)( which is placed on Main Contactor coil circuit )became
NO to NC itrsquos complete The Circuit of Main contactor Coil (KM3) so Main Contactor Coil
energized and Main Contactorrsquos Main and Auxiliary Contactor Change its Position from NO
To NC This sequence happens in a friction of time
4 After pushing the ON push button switch the auxiliary contact of the main contactor coil (2)
which is connected in parallel across the ON push button will become NO to NC thereby
providing a latch to hold the main contactor coil activated which eventually maintains the
control circuit active even after releasing the ON push button switch
5 When Star Main Contactor (KM1) close its connect Motor connects on STAR and itrsquos
connected in STAR until Time Delay Auxiliary contact KT (3) become NC to NO
6 Once the time delay is reached its specified Time the timerrsquos auxiliary contacts (KT)(3) in
Star Coil circuit will change its position from NC to NO and at the Same Time Auxiliary
contactor (KT) in Delta Coil Circuit(4) change its Position from NO To NC so Delta coil
energized and Delta Main Contactor becomes NO To NC Now Motor terminal connection
change from star to delta connection
7 A normally close auxiliary contact from both star and delta contactors (5amp6)are also placed
opposite of both star and delta contactor coils these interlock contacts serves as safety
switches to prevent simultaneous activation of both star and delta contactor coils so that one
22 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
cannot be activated without the other deactivated first Thus the delta contactor coil cannot be
active when the star contactor coil is active and similarly the star contactor coil cannot also
be active while the delta contactor coil is active
8 The control circuit above also provides two interrupting contacts to shutdown the motor
The OFF push button switch break the control circuit and the motor when necessary The
thermal overload contact is a protective device which automatically opens the STOP Control
circuit in case when motor overload current is detected by the thermal overload relay this is to
prevent burning of the motor in case of excessive load beyond the rated capacity of the motor
is detected by the thermal overload relay
9 At some point during starting it is necessary to change from a star connected winding to a
delta connected winding Power and control circuits can be arranged to this in one of two
ways ndash open transition or closed transition
What is Open or Closed Transition Starting
(1) Open Transition Starters
Discuss mention above is called open transition switching because there is an open state between
the star state and the delta state
In open transition the power is disconnected from the motor while the winding are reconfigured via
external switching
When a motor is driven by the supply either at full speed or at part speed there is a rotating
magnetic field in the stator This field is rotating at line frequency The flux from the stator field
induces a current in the rotor and this in turn results in a rotor magnetic field
When the motor is disconnected from the supply (open transition) there is a spinning rotor within
the stator and the rotor has a magnetic field Due to the low impedance of the rotor circuit the time
constant is quite long and the action of the spinning rotor field within the stator is that of a
generator which generates voltage at a frequency determined by the speed of the rotor When the
motor is reconnected to the supply it is reclosing onto an unsynchronized generator and this result
in a very high current and torque transient The magnitude of the transient is dependent on the
phase relationship between the generated voltage and the line voltage at the point of closure can
be much higher than DOL current and torque and can result in electrical and mechanical damage
Open transition starting is the easiest to implement in terms or cost and circuitry and if the timing
of the changeover is good this method can work well In practice though it is difficult to set the
necessary timing to operate correctly and disconnectionreconnection of the supply can cause
significant voltagecurrent transients
In Open transition there are Four states
23 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 OFF State All Contactors are open
2 Star State The Main [KM3] and the Star [KM1] contactors are closed and the delta [KM2]
contactor is open The motor is connected in star and will produce one third of DOL torque at one
third of DOL current
3 Open State This type of operation is called open transition switching because there is an
open state between the star state and the delta state The Main contractor is closed and the Delta
and Star contactors are open There is voltage on one end of the motor windings but the other end
is open so no current can flow The motor has a spinning rotor and behaves like a generator
4 Delta State The Main and the Delta contactors are closed The Star contactor is open The
motor is connected to full line voltage and full power and torque are available
(2) Closed Transition StarDelta Starter
There is a technique to reduce the magnitude of the switching transients This requires the use of a
fourth contactor and a set of three resistors The resistors must be sized such that considerable
current is able to flow in the motor windings while they are in circuit
The auxiliary contactor and resistors are connected across the delta contactor In operation just
before the star contactor opens the auxiliary contactor closes resulting in current flow via the
resistors into the star connection Once the star contactor opens current is able to flow round
through the motor windings to the supply via the resistors These resistors are then shorted by the
delta contactor If the resistance of the resistors is too high they will not swamp the voltage
generated by the motor and will serve no purpose
In closed transition the power is maintained to the motor at all time This is achieved by
introducing resistors to take up the current flow during the winding changeover A fourth
contractor is required to place the resistor in circuit before opening the star contactor and then
removing the resistors once the delta contactor is closed These resistors need to be sized to carry
the motor current In addition to requiring more switching devices the control circuit is more
complicated due to the need to carry out resistor switching
In Close transition there are Four states
1 OFF State All Contactors are open
2 Star State The Main [KM3] and the Star [KM1] contactors are closed and the delta [KM2]
contactor is open The motor is connected in star and will produce one third of DOL torque at one
third of DOL current
Star Transition State The motor is connected in star and the resistors are connected across the
delta contactor via the aux [KM4] contactor
24 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Closed Transition State The Main [KM3] contactor is closed and the Delta [KM2] and Star
[KM1] contactors are open Current flows through the motor windings and the transition resistors
via KM4
Delta State The Main and the Delta contactors are closed The transition resistors are shorted out
The Star contactor is open The motor is connected to full line voltage and full power and torque
are available
Effect of Transient in Starter (Open Transient starter)
It is Important the pause between star contactor switch off and Delta contactor switch is on correct
This is because Star contactor must be reliably disconnected before Delta contactor is activated It
is also important that the switch over pause is not too long
For 415v Star Connection voltage is effectively reduced to 58 or 240v The equivalent of 33
that is obtained with Direct Online (DOL) starting
If Star connection has sufficient torque to run up to 75 or 80 of full load speed then the motor
can be connected in Delta mode
When connected to Delta configuration the phase voltage increases by a ratio of V3 or 173 The
phase currents increase by the same ratio The line current increases three times its value in star
connection
During transition period of switchover the motor must be free running with little deceleration
While this is happening ldquoCoastingrdquo it may generate a voltage of its own and on connection to the
supply this voltage can randomly add to or subtract from the applied line voltage This is known as
transient current Only lasting a few milliseconds it causes voltage surges and spikes Known as
a changeover transient
Size of each part of Star-Delta starter
(1) Size of Over Load Relay
For a star-delta starter there is a possibility to place the overload protection in two positions in the
line or in the windings
Overload Relay in Line
In the line is the same as just putting the overload before the motor as with a DOL starter
The rating of Overload (In Line) = FLC of Motor
Disadvantage If the overload is set to FLC then it is not protecting the motor while it is in delta
(setting is x1732 too high)
Overload Relay in Winding
25 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
In the windings means that the overload is placed after the point where the wiring to the contactors
are split into main and delta The overload then always measures the current inside the windings
The setting of Overload Relay (In Winding) =058 X FLC (line current)
Disadvantage We must use separate short circuit and overload protections
(2) Size of Main and Delta Contractor
1 There are two contactors that are close during run often referred to as the main contractor and
the delta contactor These are AC3 rated at 58 of the current rating of the motor
Size of Main Contactor= IFL x 058
(3) Size of Star Contractor
The third contactor is the star contactor and that only carries star current while the motor is
connected in star The current in star is 1 radic3= (58) of the current in delta so this contactor can
be AC3 rated at one third (33) of the motor rating
Size of Star Contactor= IFL x 033
Motor Starting Characteristics of Star-Delta Starter
Available starting current 33 Full Load Current
Peak starting current 13 to 26 Full Load Current
Peak starting torque 33 Full Load Torque
Advantages of Star-Delta starter
The operation of the star-delta method is simple and rugged
It is relatively cheap compared to other reduced voltage methods
Good TorqueCurrent Performance
It draws 2 times starting current of the full load ampere of the motor connected
Disadvantages of Star-Delta starter
Low Starting Torque (Torque = (Square of Voltage) is also reduce)
Break In Supply ndash Possible Transients
Six Terminal Motor Required (Delta Connected)
It requires 2 set of cables from starter to motor
It provides only 33 starting torque and if the load connected to the subject motor requires higher
starting torque at the time of starting than very heavy transients and stresses are produced while
changing from star to delta connections and because of these transients and stresses many
electrical and mechanical break-down occurs
26 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
In this method of starting initially motor is connected in star and then after change over the motor
is connected in delta The delta of motor is formed in starter and not on motor terminals
High transmission and current peaks When starting up pumps and fans for example the load
torque is low at the beginning of the start and increases with the square of the speed When
reaching approx 80-85 of the motor rated speed the load torque is equal to the motor torque and
the acceleration ceases To reach the rated speed a switch over to delta position is necessary and
this will very often result in high transmission and current peaks In some cases the current peak
can reach a value that is even bigger than for a DOL start
Applications with a load torque higher than 50 of the motor rated torque will not be able to start
using the start-delta starter
Low Starting Torque The star-delta (wye-delta) starting method controls whether the lead
connections from the motor are configured in a star or delta electrical connection The initial
connection should be in the star pattern that results in a reduction of the line voltage by a factor of
1radic3 (577) to the motor and the current is reduced to 13 of the current at full voltage but the
starting torque is also reduced 13 to 15 of the DOL starting torque
The transition from star to delta transition usually occurs once nominal speed is reached but is
sometimes performed as low as 50 of nominal speed which make transient Sparks
Features of star-delta starting
1 For low- to high-power three-phase motors
2 Reduced starting current
3 Six connection cables
4 Reduced starting torque
5 Current peak on changeover from star to delta
6 Mechanical load on changeover from star to delta
Application of Star-Delta Starter
The star-delta method is usually only applied to low to medium voltage and light starting
Torque motors
The received starting current is about 30 of the starting current during direct on line start and the
starting torque is reduced to about 25 of the torque available at a DOL start This starting
method only works when the application is light loaded during the start If the motor is too heavily
27 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
loaded there will not be enough torque to accelerate the motor up to speed before switching over
to the delta position
LESSON 1 WIRING SYSTEM OF SINGLE PHASE DISTRIBUTION BOARD
Introduction
28 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
29 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
30 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
31 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 2 WIRING SYSTEM OF SINGLE PHASE LIGHTING CIRCUIT Introduction
Objectives
1 Identify component and the specification
2 Wire component according to the schematic diagram
3 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Wiring bay Perforated metal 180 cm x 180 cm 1
2 Cut out fuse 63 A 240 V 1
3 Neutral link 1
4 Single pole one way switch cw
switch box
5A 240Vac 4
5 single pole two way switch cw
switch box
5A 240Vac 2
6 RCCB In = 40 A Tripping current
100mA240 Vac 50 Hz
1
7 Main switch 32 A 240V 1
8 kWatthour meter 40 A 240 Vac 1
9 Single pole MCB 6A 240 Vac 1
10 Self tapping Wood screw As required
11 DIN rail 35 mm width As required
32 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
12 PVC trunking 50 mm x 50 mm As required
13 Terminal blocks 5 A As required
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
1 One way switch to control one lamp
2 One way switch to control two lamps
3 Two of two way switch to control one lamp
4 Two of single pole two way switch and one of an intermediate switch to control one
lamp
5 One unit of ceiling fan and fan regulator to be controlled by one way switch
4 Test the functionality of completed project
LESSON 3ndash WIRING SYSTEM OF SINGLE PHASE POWER CIRCUIT Introduction
33 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
34 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify types of component and its specification
2 Wire component according to the schematic diagram given
3 Test the functionality of the circuit dead circuit test life circuit test
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board Perforated Metal 1
2 kWh meter 240 V 40 A 1
3 Socket outlet 13A 240Vac 4
4 RCCB 40A Trip Amps
30mA240 Vac
1
5 3 pin socket 240Vac 13A 4
6 Single pole MCB 20A 240 V 2
7 DOL starter 1 kW 240Vac 2
8 1 phase induction motor 2Hp 240 Vac 1
9 Cooker control unit 4kW 240Vac 1
10 Water heater point 4kW 240 Vac 1
11 DIN rail 35 mm As required
12 PVC casing 20mm As required
13 Flexible wires 05 mm As required
14 Terminal block 10 A As required
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Wire two unit of 13 A socket outlet in radial circuit
3 Wire four units of 13 A socket outlet in ring circuit
4 Wire one unit DOL starter for air-conditioner point
5 Wire one unit of cooker control unit point
6 Wire one unit of water heater point
7 Test the functionality of each component by using mmeter or power supply whichever
applicable
8 Wire component according to circuit diagram
9 Test the functionality of completed project dead circuit test life circuit test
Note
35 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Ensure that the correct rating of protection device and size of wire used
LESSON 4ndash CONDUIT BENDING AND TRUNKING FABRICATION TECHNIQUE
Common fitting used in an industrial wiring
Cutting and threading the condute
36 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
37 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
38 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify conduit fitting and the specification
2 Measure and Cut steel conduit according to specified dimension
3 Bend and fabricate conduit at 45 90 according to layout diagram
4 Wire component according to the schematic diagram
5 Test the functionality of the circuit
39 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Conduit Bender Oslash 19 mm ( frac34 ldquo) 1
2 Measuring Tape 3 metre 1
3 Hacksaw frame and blade 30cm 1
4 Conduit cutter 1
5 Pipe Vise 1
6 Pipe Wrench 1
7 Ratchet Dies 20 mm 1
8 Metal trunking 50 mm x 50 mm 1
9 GI conduit 20mm 1
10 End box 20 mm 1
11 Flexible wires 05 mm As required
12 Connectors 5 A As required
13 Single core PVC ins Cable 25 mm 2 As required
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Wire two unit of 13 A socket outlet in radial circuit
3 Wire four unit of 13 A socket outlet in ring circuit
4 Wire one unit DOL starter for air-conditioner point
5 Wire one unit of cooker control unit point
6 Wire one unit of water heater point
7 Test the functionality of each component by using multimeter or power supply whichever
applicable
8 Wire component according to circuit diagram
9 Test the functionality of completed project
Note
Ensure that the rating of protection device and size of wire
K prior to 31 March
2004 (BS 7671)
(formerly)
bare conductor
sleeved at terminations (formerly)
40 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 5 ndashWIRING SYSTEM OF 1 Oslash LIGHTING AND POWER CIRCUIT
POWER CIRCUITSa Radial circuits
Radial circuits are arranged in the same way as item 1 above in lighting layouts in that each socket
outlet is supplied via the previous one
Points to note
1 The number of socket outlets complying with BS 1363 is unlimited for a floor area of up to 50m 2 if
the circuit protection is a 30 A or 32 A cartridge fuse or circuit breaker the cable being 4 mm PVC
copper or 25 mm2 mineral insulated (mi)
2 The number of socket outlets is unlimited for a floor area up to 20 m 2 with any type of circuit
protection of 20 A using 25 mm2 PVC copper cable or 15 mm2 mi
3 The total number of fused spurs is unlimited
b ring final circuits
These circuits are the same as radial circuits except that the final socket outlet is wired back to the
supply position In effect any outlet is supplied from two directions (Fig 152)
Points to note
1 Every twin-socket outlet counts as two single-socket outlets
2 The number of non-fused spurs must not exceed the total number of points on the ring Fig 158
shows seven points on the ring and five spurs
3 The fuse rating of a fused spur box must not exceed 13 A and the current rating of all points supplied
by the fused spur must not exceed 13 A
4 Non-fused spurs must supply no more than one single or one double socket on the ring Fig 158
shows seven points on the ring and five spurs rating of all points supplied by the fused spur must not
exceed 13 A or one stationary appliance
CapacityMain conductor size
copper (mm2)
Earth conductor
size (mm2)
Circuit breaker
capacity (A)
Up to 600 W 15 15 6
600ndash1200 W 1525 15 10
1200ndash1800 W 254 25 16
41 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Ring circuit
(floor area 100 m2)25 15 3032
A2 radial circuit
(floor area 75 m2)40 25 3032
A3 radial circuit
(floor area 50 m2)25 15 20
Air conditioner (15 tonne) 60 60 3032
Cooker 60 60 3032
Water heater 40 40 20
Objectives
1 Identify component and the specification
2 Wire component according to the schematic diagram
3 Test the functionality of the circuit
42 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board Perforated 1
2 Cut out fuse and neutral link 60A 240V 1each
3 kWh meter 240V 40A 1
4 Switched Socket outlet 13A 240Vac 4
5 Single pole two way switch cw switch
box
5A 240Vac 2
6 RCCB ELCB 63 A Tripping current 100mA
415 Vac
1
7 3 pin plug 240Vac 13A 4
8 Single pole MCB 20 A 2
9 Single pole MCB 6A 1
10 Single pole MCB 20A 2
11 DOL starter 240Vac 2
12 1 phase induction motor 2hp 240 Vac 1
13 Self tapping Wood screw As required
14 DIN rail Stainless steel allum35 mm As required
15 PVC pipe 20mm dia As required
16 End box 20 mm dia 4
17 Flexible wires 05 mm 2 As required
18 Connectors 5 A As required
Procedures
43 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
4 Test the functionality of completed project
LESSON 6 ndash WIRING SYSTEM OF 3 Oslash DISTRIBUTION BOARD
Introduction
44 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
45 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
46 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
47 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
48 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify each component and the specification
2 Wire component according to the schematic diagram given
3 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting Board 450 x 600 mm Perforated metal 1
2 5 pin round socket and plug 415V ac 32A 1
3 Cut out fuse 60 A 3
4 Neutral link 1
5 kWatt hour meter 415V 60A 1
6 ELCB RCCB 3P+N In=63A415 Vac I trip= 300mA 1
7 ELCB RCCB 3P+N In=63A415 Vac I trip= 30mA 1
8 Single pole MCB 6A 240 V 3
9 Single pole MCB 20A 240 V 3
10 DOL starter 20 A 240Vac 2
11 Socket outlet 15 A 240 Vac 1
12 Switched Socket outlet 13 A 240 Vac 3
13 Led indicating light 5A 240 Vac 3
14 Single pole 4 gang 1 way switch 5A 240 Vac 2
15 Single pole 2 way switch 5A 240 Vac 2
16 1 phase induction motor 1 kW 240Vac 1
17 Metal trunking 30 mm x30 mm As required
18 Self tapping Wood screw 4 mm x 20 mm As required
19 DIN rail 25 mm x 1mm
20 GI steel rigid conduit 20mm As required
21 Flexible conduit 20mm As required
22 End box 20 mm 4
23 Flexible wires 05 mm 2 As required
24 Single core PVC insulated wire 15 mm 2 As required
25 Single core PVC insulated wires 25 mm 2 As required
26 Terminal block 10 A As required
Procedures
49 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify each components and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
4 Test the functionality of completed project
1 dead circuit test
2 life circuit
Note Proper earthing should be made
50 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 7 ndash WIRING SYSTEM OF THREE PHASE LIGHTING AND POWER CIRCUIT
51 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
52 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify component and the specification
2 Wire component according to the schematic diagram
3 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting bay Board Perforated metal 180 cm x 180 cm 1
2 k Watt hour meter 415V 60A 1
3 MCCB 415V 60A
4 ELCB RCCB In=60A415 Vac I trip=30mA 1
5 5 pin round Socket and
plug
415Vac 32A 4
6 Single pole MCB 6A 1
7 Triple pole MCB 20A 2
8 Triple pole Main switch 60A 1
9 DOL starter 240Vac 2
10 3 phase induction motor 2hp 415 Vac 1
11 1 phase induction motor 1
12 Metal trunking 30 mm x30 mm As required
13 Self tapping Wood screw 4 mm x 20 mm As required
14 DIN rail 25 mm x 1mm
15 GI steel rigid conduit 20mm As required
16 Flexible conduit 20mm As required
17 End box 20 mm 4
18 Flexible wires 05 mm As required
19 Connectors 10 A As required
Procedures
1 Identify each components and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
4 Test the functionality of completed project
1 dead circuit 2 life circuit test
5 Record the current drawn by the load as connected in star and delta
Note Proper earthing should be made
53 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 8 INSPECTION AND TESTING OF ELECTRICAL INSTALLATION
On completion of a wiring installation a number of tests on the installation have to be conducted to
ascertain that the wiring circuits and connected appliances are safe for use Prior to carrying out the
tests an inspection has to be done The results of the inspectionsupervision and test have to be
presented in Form G (as in Appendix IV) and Form H (as in Appendix V)
To have the test certification as in Form H the following tests shall be conducted
i Continuity Test
ii Insulation Resistance Test
iii Polarity Test
iv Earth Electrode Resistance test and
v Residual Current Device Test
1 Continuity Test
There are 3 main types of continuity tests for the final circuits-
i Protection Conductor Continuity Test
ii Final Ring Circuit Conductor Continuity Test
iii Live and Neutral Conductor Continuity Test
a) Protection Conductor Continuity Test
bull To ascertain that all protection conductors are connected in the correct and effective manner
bull Test equipment ndash Multimeter (Ohm range) or Ohm meter
54 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
bull Test Method
1 1048766 Ensure that the main switch RCD and MCB are open circuited (switched off) and all loads
are disconnected
2 1048766 Connected the test leads as in the Figure 81 The meter reading shall be less than 1 Ω
55 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Final Ring Circuit Conductor Continuity Test
bull To ensure that all conductors around the ring circuit have continuity
bull Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
bull Test Method
1 1048766 Disconnect both the supply source live conductors from the MCB the neutral conductor
from the neutral terminals and the earth conductor from the earth terminal in the distribution
fuse box
2 1048766 Connect the test leads as in the Figure 82 (EE)
3 1048766 Repeat the procedure for (L-L) and (N-N)
4 1048766 The meter reading value shall be less than 1 ohm
56 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Live and Neutral Conductor Continuity Test
a To ensure that each conductor in the circuit has continuity
b Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
2 Test Method
1 1048766 Switch off the Main switch RCD and MCB
2 1048766 Disconnect all loads
3 1048766 Switch on all switches in the circuit
4 1048766 Disconnect the fusesfinal circuit breakers and close the circuit
5 1048766 Carry out the test as shown in Figure 83
6 1048766 The meter reading value shall be less than 1Ω
57 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
58 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
CONTINUITY TEST
Insulation Resistance Test
i Ensure that there is no leakage current between phase conductors phase and neutral conductors and
phase conductor and earth
ii Test the strength of the cable insulation
iii Test Equipment ndash Insulation Resistance Tester operating voltage is 250VDC or 500VDC
iv Test Method
1 1048766 Switch off main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
59 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
4 1048766 Carry out test as in the Table below
5 1048766 Meter reading value shall be less than 1 Megaohm
60 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
61 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Insulation resitance test
62 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
INSULATION RESISTANCE TEST BETWEEN CONDUCTORS AND OPPOSITE POLARITY
Polarity Testi Ensure that each fuse or single pole control and protection device is connected only in the phase
conductor
ii Intermediate contact of Edison screw lamp holder is connected to the phase conductor
iii Ensure that phase neutral and earth conductors at socket outlets are connected at the correct
terminals
iv Test Equipment ndash Multimeter (Ohm range) or Ohm meter
v Test Method
1 1048766 Switch off Main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in Figure 85
63 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
5 1048766 Test switches and single phase control devices at the phase conductors
6 1048766 Test socket outlet connection sources
7 1048766 Test Edison screw lamp holder connections
8 1048766 Meter reading value shall be less than 1 Ω
64 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Polarity test
65 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Earth Electrode Resistance Testi To test the earth electrode resistance
ii To ascertain the suitability of the location of the electrode
iii To ensure that the electrode is not buried within the resistance area of another electrode
iv Test equipment ndash Earth Resistance Tester
v Test method -
1 1048766 Terminal rsquoErsquo is connected to the electrode to be tested (green conductor)
2 1048766 Terminal lsquoPrsquo is connected to the potential spike (yellow conductor) at a distance of 10
meters from the earth electrode
3 1048766 Terminal lsquoCrsquo is connected to the current spike (red conductor) at a distance of 20 meters
from the earth electrode
Earth Electrode Resistance Measurement Method (Figure 86)
This test must be repeated at least three times to ensure that the reading is not affected by interacting
earthing regions
i Record the first reading (Z1) Example Z1 = 10 Ω
ii Move the voltage spike to a distance of 6 meters from the original position Record the second
reading (Z2 ) Example Z2 = 10 Ω
iii Move the voltage spike to a distance of 6 meters from the original position Record the third
reading (Z3) Example Z3 = 10 Ω
66 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Residual Current Device Testi Ensure that the residual current device (RCD) trips within the set time on the occurrence of current
leakage to earth
ii Test Equipment ndash RCD Tester RCCB Tester
iii Test Method 1
1 1048766 Use the Trip Test Button
2 1048766 Press the trip button found on the RCD to determine if it trips or otherwise This test would
not be able to determine the sensitivity of the RCD nor the time taken for it to trip
iv Test Method 2
i 1048766 Use a RCD Tester
ii This equipment is equipped with a 13A plug which can be connected to a 13A socket outlet
Select the RCD sensitivity to be the same as the sensitivity of the RCD to be tested to
determine if the RCD can trip The time to trip shall not exceed 40 mS
iii 1048766 Test method ndash
a) Position the selection switch in accordance with the sensitivity of the RCD used
Example 100 mA 01 A
b) Position the operations switch to lsquoNo Triprsquo (frac12 Rated mA = 50) connect the 3 pin plug to
the 13A socket outlet
67 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
c) Switch on the 13A socket outlet ndash ensure that the P-N and P-E lights light up
This shows that the polarity is correct (Note if both the lights as above do not light up the test cannot
be continued)
d) Press the test button ndash the reading shows less than 200 mS and simultaneously the lsquotestrsquo light lights
up and the P-N and P-E lights do not light up At that instant the RCD will not trip
e) Move the selection switch to 180o (+ve wave) ndash repeat steps (d) and (e) Move the operations
switch to lsquoTriprsquo (Rated mA = 100)
g) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200mS
h) Move the selection switch to 0o (-ve wave)
i) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
j) The above test is repeated until a near correct reading is obtained
k) Record the test results
l) Change the operations switch to lsquoFast Triprsquo and press the test button ndash RCD will trip within a
time not exceeding 40 millisecond
m) Repeat a number of times at 0o or 180o
On completion of a wiring installation a number of tests on the installation have to be conducted to
ascertain that the wiring circuits and connected appliances are safe for use Prior to carrying out the
tests an inspection has to be done the following tests shall be conducted
i Continuity Test
ii Insulation Resistance Test
iii Polarity Test
iv Earth Electrode Resistance test and
v Residual Current Device Test
821 Continuity Test
There are 3 main types of continuity tests for the final circuits-
i Protection Conductor Continuity Test
ii Final Ring Circuit Conductor Continuity Test
68 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
iii Live and Neutral Conductor Continuity Test
a) Protection Conductor Continuity Test
bull To ascertain that all protection conductors are connected in the correct and effective manner
bull Test equipment ndash Multimeter (Ohm range) or Ohm meter
bull Test Method
1 1048766 Ensure that the main switch RCD and MCB are open circuited (switched off) and all loads are
disconnected
2 1048766 Connected the test leads as in the Figure 81
3 1048766 The meter reading shall be less than 1 Ω
Final Ring Circuit Conductor Continuity Test
bull To ensure that all conductors around the ring circuit have continuity
bull Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
bull Test Method
1 1048766 Disconnect both the supply source live conductors from the MCB the neutral conductor
from the neutral terminals and the earth conductor from the earth terminal in the distribution
fuse box
2 1048766 Connect the test leads as in the Figure 82 (EE)
3 1048766 Repeat the procedure for (L-L) and (N-N)
4 1048766 The meter reading value shall be less than 1 ohm Figure 82 - Final Ring Circuit Conductor
Continuity Test Ohm Meter
Disconnect both the supply source cables from mcbfuse
Take readings at earth conductors of both sources and note resistance readings
Live and Neutral Conductor Continuity Test
1 To ensure that each conductor in the circuit has continuity
2 Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
3 Test Method
1 1048766 Switch off the Main switch RCD and MCB
2 1048766 Disconnect all loads
3 1048766 Switch on all switches in the circuit
4 1048766 Disconnect the fusesfinal circuit breakers and close the circuit
5 1048766 Carry out the test as shown in Figure 83
6 1048766 The meter reading value shall be less than 1 ohm Figure 83 - Live and Neutral
Conductor Continuity Test Ohm Meter
Insulation Resistance Test
69 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
i Ensure that there is no leakage current between phase conductors phase and neutral conductors and
phase conductor and earth
ii Test the strength of the cable insulation
iii Test Equipment ndash Insulation Resistance Tester Operating voltage is 250VDC or 500VDC
iv Test Method
1 1048766 Switch off main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in the Table below
5 1048766 Meter reading value shall be less than 1 Megaohm
Polarity Test
i Ensure that each fuse or single pole control and protection device is connected only in the phase
conductor
ii Intermediate contact of Edison screw lamp holder is connected to the phase conductor
iii Ensure that phase neutral and earth conductors at socket outlets are connected at the correct
terminals
iv Test Equipment ndash Multimeter (Ohm range) or Ohm meter
v Test Method
1 1048766 Switch off Main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in Figure 85
5 1048766 Test switches and single phase control devices at the phase conductors
6 1048766 Test socket outlet connection sources
7 1048766 Test Edison screw lamp holder connections
8 1048766 Meter reading value shall be less than 1 Ω
Earth Electrode Resistance Test
i To test the earth electrode resistance
70 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
ii To ascertain the suitability of the location of the electrode
iii To ensure that the electrode is not buried within the resistance area of another electrode
iv Test equipment ndash Earth Resistance Tester
v Test method -
1 1048766 Terminal rsquoErsquo is connected to the electrode to be tested (green conductor)
2 1048766 Terminal lsquoPrsquo is connected to the potential spike (yellow conductor) at a distance of 10
meters from the earth electrode
3 1048766 Terminal lsquoCrsquo is connected to the current spike (red conductor) at a distance of 20 meters
from the earth electrode E P C Electrode 10 meter 10 meter
Figure 86 ndash Earth Electrode Resistance Measurement Test Equipment
Earth Electrode Resistance Measurement Method (Figure 86)
This test must be repeated at least three times to ensure that the reading is not affected by interacting
earthing regions
i Record the first reading (Z1) Example Z1 = 10 Ω
ii Move the voltage spike to a distance of 6 meters from the original position Record the second
reading (Z2) Example Z2 = 10 Ω
iii Move the voltage spike to a distance of 6 meters from the original position Record the third
reading (Z3)
Example Z3 = 10 Ω
Residual Current Device Test
71 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
i Ensure that the residual current device (RCD) trips within the set time on the occurrence of current
leakage to earth
ii Test Equipment ndash RCD Tester RCCB Tester
iii Test Method 1
1 1048766 Use the Trip Test Button
2 1048766 Press the trip button found on the RCD to determine if it trips or otherwise This test would
not be able to determine the sensitivity of the RCD nor the time taken for it to trip
iv Test Method 2
1048766 Use a RCD Tester
This equipment is equipped with a 13A plug which can be connected to a 13A socket outlet Select the
RCD sensitivity to be the same as the sensitivity of the RCD to be tested to determine if the RCD can
trip The time to trip shall not exceed 40 mS
1048766 Test method ndash
a) Position the selection switch in accordance with the sensitivity of the RCD used
Example 100 mA 01 A
b) Position the operations switch to lsquoNo Triprsquo (frac12 Rated mA = 50) connect the 3 pin plug to
the 13A socket outlet
c) Switch on the 13A socket outlet ndash ensure that the P-N and P-E lights light up This shows that
the polarity is correct (Note if both the lights as above do not light up the test cannot be
continued)
d) Press the test button ndash the reading shows less than 200 millisecond and simultaneously the
lsquotestrsquo light lights up and the P-N and P-E lights do not light up At that instant the RCD will
not trip
e) Move the selection switch to 180o (+ve wave) ndash repeat steps (d) and (e) = 100)
f) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
g) Move the selection switch to 0o (-ve wave)
h) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
i) The above test is repeated until a near correct reading is obtained
j) Record the test results
k) Change the operations switch to lsquoFast Triprsquo and press the test button ndash RCD will trip within a
time not exceeding 40 mS
l) Repeat a number of times at 0o or 180o
72 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 9 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (DC)
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
73 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Start stop button 240Vac 5A 2
9 Filament lamp (Bulb ) 240Vac 40W 3
10 Overload Relay 415V 20A 3
11 Three phase induction motor 5 hp 3
12 Single phase step down transformer 2500VA 1
13 Single core PVC insulated Cable 1mm 2 As required
14 Single core PVC insulated Cable 25mm 2 As required
15 DIN rail 35 mm As required
16 PVC type Cable tray 50 mm x 50 mm As required
17 Cable ties 4 ldquo As required
18 Flexible wires 05 mm As required
19 PVC Connectors 5 A amp 20 A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the schematic
diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a optional exercise
i Simple DOL starter
ii Forward reverse DOL starter
iii Forward Reverse Dahlander motor
iv Three motors operated in sequence by DOL starter operated by manual push
button or time delay relay
74 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
a One loop per-cycle
b Continuous operation in a loop
c optional circuit design to represent the same task
v Only one out of three motors to be operated at a time (quiz)
4 Test the functionality of completed project
LESSON 10 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (AC)
75 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 1
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Lamp point 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
76 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
11 Overload Relay 415V 20A 3
12 Three phase induction
motor
5 hp 3
13 Single core PVC insulated
Cable
1mm 2 As required
14 Single core PVC insulated
Cable
25mm 2 As required
15 DIN rail 35 mm As required
16 PVC type Cable tray 50 mm x 50 mm As required
17 Cable ties 4 ldquo As required
18 Flexible wires 05 mm As required
19 PVC Connectors 5 A amp 20 A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the
schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram optional exercise
4 Simple DOL starter
5 Forward reverse DOL starter
6 Test the functionality of completed project
77 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 1
78 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
cm
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Indicating light 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
11 Overload Relay 415V 20A 3
12 Three phase induction motor 5 hp 3
13 Single phase step down
transformer
2500VA 1
14 Single core PVC insulated
Cable
1mm 2 As required
15 Single core PVC insulated
Cable
25mm 2 As required
16 DIN rail 35 mm As required
17 PVC type Cable tray 50 mm x 50 mm As required
18 Cable ties 4 ldquo As required
19 Flexible wires 05 mm As required
20 PVC Connectors 5 A amp 20 A 240 V As required
21 Single pole MCB 6A 240 V 1
22 Single pole MCB 2A 240 V 1
23 Triple pole MCB 20A 415 V 1
24 Mounting board 30 cm x 40 cm x 3
cm
1
25 Relay cw 11 pin socket 10 A 240 Vac 2
26 Time delay relay 10 A 240 Vac 3
27 Triple pole Contactor 20A 240Vac 3
28 Batten type Lamp holder 240Vac 10 A 3
29 Start stop button 240Vac 10A 2
30 Indicating light (Bulb ) 240Vac 25W 3
31 Overload Relay 415V 20A 1
32 Three phase dahlander type
induction motor
5 hp 1
33 Single phase step down
transformer
24024Vac
2500VA
1
79 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
34 Single core PVC insulated
Cable
1mm 2 As required
35 Single core PVC insulated
Cable
25mm 2 As required
36 DIN rail 35 mm As required
37 PVC type Cable tray 50 mm x 50 mm As required
38 Cable ties 4 ldquo As required
39 Flexible wires 075 mm As required
40 PVC Connectors 5 A amp 20 A 240 V As required
41 Terminal block 20A 240Vac As required
Procedures
5 Identify each component according to specification and quantity required from the schematic
diagram attached
6 Test the functionality of each component by using multi-meter or power supply whichever
applicable
7 Wire component according to circuit diagram
8 Three motors operated in sequence by DOL starter operated by manual push button or time
delay relay
a One loop per-cycle
b Continuous operation in a loop
c optional circuit design to represent the same task
d Only one out of three motors to be operated at a time (quiz)
9 Test the functionality of completed project
80 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
BASIC DESIGN INDUSTRIAL MOTOR CONTROL (SEQUENCE CONTROL)
THREE PHASE INDUCTION MOTOR OPERATED IN SEQUENCE BY DIRECT ON LINE
STARTER
LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
81 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
82 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Lcd lamp indicator 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
11 Overload Relay 415V 20A 3
12 Three phase induction motor 5 hp 3
13 Single phase step down transformer 2500VA 1
14 Single core PVC insulated Cable 1mm 2 As required
15 Single core PVC insulated Cable 25mm 2 As required
16 DIN rail 35 mm As required
17 PVC type Cable tray 50 mm x 50 mm As required
18 Cable ties 4 ldquo As required
19 Flexible wires 1 mm Oslash As required
20 PVC Terminal block 10A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the schematic
diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a optional exercise
i Forward Reverse dahlander motor
4 Test the functionality of completed project
83 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
THREE PHASE DAHLANDER TYPE INDUCTION MOTOR OPERATED FORWARD AND
REVERSE OPERATION BY DIRECT ON LINE STARTER
84 ndash 99EASYTECH ENTERPRISE
LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
Introduction
If a motors windings are connected in the star configuration any two phases will be in series across
the supply and hence the line current will be smaller(by 577) than if the windings were connected in
the delta arrangement
Hence larger-type motors with heavy starting currents are first connected in star and then when the
starting currents fall in delta This of course means that all six of the ends of the windings must be
brought to terminations outside the casing (Fig 833)
EZTECH
EZTECH ELECTRICAL INSTALLATION GUIDE
The automatic version of this starter incorporates a timing relay which automatically changes the
connections from star to delta Figs 834 and 835 show the wiring and schematic diagrams for a star
delta starter
Objectives
1 Identify component and the specification
2 Design forward reverse star delta starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
2 ndash 99EASYTECH ENTERPRISE
REV -C
LEGENDMCCB Moulded Case Circuit BreakerTOR Thermal Over Load RelayFOW-C Mains Forward ContactorREV-C Mains Reverse ContactorDC Delta ContactorSC Star ContactorS-SW Mains Selector Switch
SC
V2
W2
U2
DC
V1
W1
U1
TOR
TOR
FOW-C
30A MCCB
TOR
MAIN CIRCUIT FORWARD REVERSE STAR DELTA
RYBN S
-SW
3 PHASEINDUCTION MOTOR
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Relay 10 A 240V 3
5 Triple pole Contactor
6 cw NO NC auxiliary contact
240Vac 20 A 4
7 Overload Relay 415 V 1
8 LED indicator 240vac 5 A 4
9 Start stop button 240Vac 5A 2
10 DIN rail 35 mm As required
11 Flexible wires 1 mm As required
12 Single core PVC insulated
wire
25 mm As required
13 Terminal block 20 A As required
14 Squirrel cage motor 5kW 1
15 5 pin plug and socket 415V 20A 1
16 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
3 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
a Manual star delta
b Manual Forward reverse star delta starter
c Automatic star delta starter
d Automatic Forward reverse star delta starter
4 Test the functionality of completed project
4 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
Objectives
1 Identify component and the specification
2 Design auto transformer starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
5 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Autotransformer starter is used to start a 3 phase induction motor that has a rating between 10 to 15 hp
6 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Autotransformer set 10Kw 415 V 50 Hz 1
5 Triple pole Contactor 240Vac 4
6 Batten type Lamp holder 240 Vac 105 A 4
7 Start stop button 240Vac 10A 4
8 Filament lamp (Bulb ) 240Vac 40W 4
9 DIN rail 35 mm As required
10 Flexible wires 1 mm As required
7 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
11 Single core PVC insulated
wire
25 mm As required
12 Terminal block 20 A As required
13 Squirrel cage motor 10kW 1
14 5 pin plug and socket 415V 20A 1
15 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a open transient autotransformer starter
b close transient autotransformer starter
c Forward reverse autotransformer starter
4 Test the functionality of completed project
8 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
Objectives
1 Identify component and the specification
2 Design rotor resistance starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
9 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Rotor Resistor set 10kW 1
5 Triple pole Contactor 240Vac 20A 4
6 Indicating light 240vac 5 A 4
7 Start stop push button 240Vac 5A 4
8 DIN rail 35 mm As required
9 Flexible wires 1 mm 2 As required
10 Single core PVC insulated wire 25 mm 2 As required
11 Terminal block 20 A As required
12 Slip Ring motor 10kW 1
13 5 pin round 3 phase socket 415V 20A 1
14 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
10 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
4 Test the functionality of completed project
a Dead circuit test b Life circuit test
5 Measure starting and running Amps
LESSON 16
TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
An installation in general will suffer damage
Damage usually occurs on the electric motor control as follows
1 Damage to the main circuit
2 Damage to the control circuit
The cause of the damage
i Overcurrent overload short circuit
ii Leakage current to ground
iii Equipment malfunction
iv The main control circuit
a Trip of main circuit protection devices fire
b Defect of motor terminal such as short circuit fire loose
v The control circuit is not functioning -
a contactor relay relay time overload relay does not work damaged burned
b Loose cable connection disconnected
Detecting and Repairing Damage
Examples of damage are as follows
i Motor does not work
ii Motor function and overload relay trips
iii Motor function but only partially functional control circuit
Methods of detecting damage
Among the known methods necessary to detect damage are as follows
1 Turn off the electricity at the main switch (main switch) in order to avoid any danger during the
work carried out to detect damage
2 Check all the protective gear that controls the motor control main circuit
11 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
3 Make sure the damage function control circuit
4 Check the control circuit according to the schematic circuit diagram of the motor control
5 Check the operation of the control circuit
Note
Use wiring that has been installed on the SYSTEM OF MOTOR CONTROL BOARD by Forward
Reverse control circuit for Star Delta to test and look for damage
SELF-ASSESSMENT QUESTIONS
1 (a) Explain what is meant by the term lsquoback emfrsquo in a motor
(b) Outline the basic differences between series shunt and compound wound dc motors
2 (a) With the aid of diagrams explain how the speed of series shunt and compound-wound motors
may be controlled
(b) A 440V dc shunt-wound motor has a field resistance of 200R and an armature resistance of 06 R
When its speed is 20 rev d second the current drawn from the supply is 122A Calculate its back
emf at this speed If the speed were decreased to 19 revssecond the field flux remaining unchanged
calculate the new back emf and the new armature current
3 A load of 64 kW at 240 V is supplied from the terminals of a shunt-wound dc generator The field
resistance is 180 A Calculate the armature current
4 (a) Explain with the aid of a diagram how a rotating magnetic field may be
(b) What is meant by lsquosynchronous speedrsquo
Calculate the synchronous obtained speed of a 12 pole motor if the supply frequency is 50Hz
5 (a) Explain the action of a synchronous motor
(b) What methods are available to start a synchronous motor Explain with diagrams
6 (a) Explain the action of a cage induction motor
(b) What is meant by the term lsquosliprsquo
Calculate the percentage slip of a six pole induction motor running at 162 revssecond from a 50 Hz
supply
7 Describe with sketches three different ways of starting a single-phase induction motor
12 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
8 Explain with the aid of a sketch the action of a three-phase DOL starter
What are dashpots used for How are remote start and stop buttons connected
9 A I0 kW 240V 50Hz single-phase cage rotor induction motor is 85efficient and has a PF of 068
lagging Calculate the motor current and the value of capacitor required to raise the PF to 093
lagging
10 Calculate the torque developed by an 18 kW four-pole induction motor run at 35 slip from a
50Hz supply
APPENDIX 1
13 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 11
14 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 111
Attachment Reference
httpswwwtlc-directcoukBook621htm
httpwwwstgovmyindexphpms
15 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
cannot be activated without the other deactivated first Thus the delta contactor coil cannot be
active when the star contactor coil is active and similarly the star contactor coil cannot also
be active while the delta contactor coil is active
8 The control circuit above also provides two interrupting contacts to shutdown the motor
The OFF push button switch break the control circuit and the motor when necessary The
thermal overload contact is a protective device which automatically opens the STOP Control
circuit in case when motor overload current is detected by the thermal overload relay this is to
prevent burning of the motor in case of excessive load beyond the rated capacity of the motor
is detected by the thermal overload relay
9 At some point during starting it is necessary to change from a star connected winding to a
delta connected winding Power and control circuits can be arranged to this in one of two
ways ndash open transition or closed transition
What is Open or Closed Transition Starting
(1) Open Transition Starters
Discuss mention above is called open transition switching because there is an open state between
the star state and the delta state
In open transition the power is disconnected from the motor while the winding are reconfigured via
external switching
When a motor is driven by the supply either at full speed or at part speed there is a rotating
magnetic field in the stator This field is rotating at line frequency The flux from the stator field
induces a current in the rotor and this in turn results in a rotor magnetic field
When the motor is disconnected from the supply (open transition) there is a spinning rotor within
the stator and the rotor has a magnetic field Due to the low impedance of the rotor circuit the time
constant is quite long and the action of the spinning rotor field within the stator is that of a
generator which generates voltage at a frequency determined by the speed of the rotor When the
motor is reconnected to the supply it is reclosing onto an unsynchronized generator and this result
in a very high current and torque transient The magnitude of the transient is dependent on the
phase relationship between the generated voltage and the line voltage at the point of closure can
be much higher than DOL current and torque and can result in electrical and mechanical damage
Open transition starting is the easiest to implement in terms or cost and circuitry and if the timing
of the changeover is good this method can work well In practice though it is difficult to set the
necessary timing to operate correctly and disconnectionreconnection of the supply can cause
significant voltagecurrent transients
In Open transition there are Four states
23 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 OFF State All Contactors are open
2 Star State The Main [KM3] and the Star [KM1] contactors are closed and the delta [KM2]
contactor is open The motor is connected in star and will produce one third of DOL torque at one
third of DOL current
3 Open State This type of operation is called open transition switching because there is an
open state between the star state and the delta state The Main contractor is closed and the Delta
and Star contactors are open There is voltage on one end of the motor windings but the other end
is open so no current can flow The motor has a spinning rotor and behaves like a generator
4 Delta State The Main and the Delta contactors are closed The Star contactor is open The
motor is connected to full line voltage and full power and torque are available
(2) Closed Transition StarDelta Starter
There is a technique to reduce the magnitude of the switching transients This requires the use of a
fourth contactor and a set of three resistors The resistors must be sized such that considerable
current is able to flow in the motor windings while they are in circuit
The auxiliary contactor and resistors are connected across the delta contactor In operation just
before the star contactor opens the auxiliary contactor closes resulting in current flow via the
resistors into the star connection Once the star contactor opens current is able to flow round
through the motor windings to the supply via the resistors These resistors are then shorted by the
delta contactor If the resistance of the resistors is too high they will not swamp the voltage
generated by the motor and will serve no purpose
In closed transition the power is maintained to the motor at all time This is achieved by
introducing resistors to take up the current flow during the winding changeover A fourth
contractor is required to place the resistor in circuit before opening the star contactor and then
removing the resistors once the delta contactor is closed These resistors need to be sized to carry
the motor current In addition to requiring more switching devices the control circuit is more
complicated due to the need to carry out resistor switching
In Close transition there are Four states
1 OFF State All Contactors are open
2 Star State The Main [KM3] and the Star [KM1] contactors are closed and the delta [KM2]
contactor is open The motor is connected in star and will produce one third of DOL torque at one
third of DOL current
Star Transition State The motor is connected in star and the resistors are connected across the
delta contactor via the aux [KM4] contactor
24 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Closed Transition State The Main [KM3] contactor is closed and the Delta [KM2] and Star
[KM1] contactors are open Current flows through the motor windings and the transition resistors
via KM4
Delta State The Main and the Delta contactors are closed The transition resistors are shorted out
The Star contactor is open The motor is connected to full line voltage and full power and torque
are available
Effect of Transient in Starter (Open Transient starter)
It is Important the pause between star contactor switch off and Delta contactor switch is on correct
This is because Star contactor must be reliably disconnected before Delta contactor is activated It
is also important that the switch over pause is not too long
For 415v Star Connection voltage is effectively reduced to 58 or 240v The equivalent of 33
that is obtained with Direct Online (DOL) starting
If Star connection has sufficient torque to run up to 75 or 80 of full load speed then the motor
can be connected in Delta mode
When connected to Delta configuration the phase voltage increases by a ratio of V3 or 173 The
phase currents increase by the same ratio The line current increases three times its value in star
connection
During transition period of switchover the motor must be free running with little deceleration
While this is happening ldquoCoastingrdquo it may generate a voltage of its own and on connection to the
supply this voltage can randomly add to or subtract from the applied line voltage This is known as
transient current Only lasting a few milliseconds it causes voltage surges and spikes Known as
a changeover transient
Size of each part of Star-Delta starter
(1) Size of Over Load Relay
For a star-delta starter there is a possibility to place the overload protection in two positions in the
line or in the windings
Overload Relay in Line
In the line is the same as just putting the overload before the motor as with a DOL starter
The rating of Overload (In Line) = FLC of Motor
Disadvantage If the overload is set to FLC then it is not protecting the motor while it is in delta
(setting is x1732 too high)
Overload Relay in Winding
25 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
In the windings means that the overload is placed after the point where the wiring to the contactors
are split into main and delta The overload then always measures the current inside the windings
The setting of Overload Relay (In Winding) =058 X FLC (line current)
Disadvantage We must use separate short circuit and overload protections
(2) Size of Main and Delta Contractor
1 There are two contactors that are close during run often referred to as the main contractor and
the delta contactor These are AC3 rated at 58 of the current rating of the motor
Size of Main Contactor= IFL x 058
(3) Size of Star Contractor
The third contactor is the star contactor and that only carries star current while the motor is
connected in star The current in star is 1 radic3= (58) of the current in delta so this contactor can
be AC3 rated at one third (33) of the motor rating
Size of Star Contactor= IFL x 033
Motor Starting Characteristics of Star-Delta Starter
Available starting current 33 Full Load Current
Peak starting current 13 to 26 Full Load Current
Peak starting torque 33 Full Load Torque
Advantages of Star-Delta starter
The operation of the star-delta method is simple and rugged
It is relatively cheap compared to other reduced voltage methods
Good TorqueCurrent Performance
It draws 2 times starting current of the full load ampere of the motor connected
Disadvantages of Star-Delta starter
Low Starting Torque (Torque = (Square of Voltage) is also reduce)
Break In Supply ndash Possible Transients
Six Terminal Motor Required (Delta Connected)
It requires 2 set of cables from starter to motor
It provides only 33 starting torque and if the load connected to the subject motor requires higher
starting torque at the time of starting than very heavy transients and stresses are produced while
changing from star to delta connections and because of these transients and stresses many
electrical and mechanical break-down occurs
26 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
In this method of starting initially motor is connected in star and then after change over the motor
is connected in delta The delta of motor is formed in starter and not on motor terminals
High transmission and current peaks When starting up pumps and fans for example the load
torque is low at the beginning of the start and increases with the square of the speed When
reaching approx 80-85 of the motor rated speed the load torque is equal to the motor torque and
the acceleration ceases To reach the rated speed a switch over to delta position is necessary and
this will very often result in high transmission and current peaks In some cases the current peak
can reach a value that is even bigger than for a DOL start
Applications with a load torque higher than 50 of the motor rated torque will not be able to start
using the start-delta starter
Low Starting Torque The star-delta (wye-delta) starting method controls whether the lead
connections from the motor are configured in a star or delta electrical connection The initial
connection should be in the star pattern that results in a reduction of the line voltage by a factor of
1radic3 (577) to the motor and the current is reduced to 13 of the current at full voltage but the
starting torque is also reduced 13 to 15 of the DOL starting torque
The transition from star to delta transition usually occurs once nominal speed is reached but is
sometimes performed as low as 50 of nominal speed which make transient Sparks
Features of star-delta starting
1 For low- to high-power three-phase motors
2 Reduced starting current
3 Six connection cables
4 Reduced starting torque
5 Current peak on changeover from star to delta
6 Mechanical load on changeover from star to delta
Application of Star-Delta Starter
The star-delta method is usually only applied to low to medium voltage and light starting
Torque motors
The received starting current is about 30 of the starting current during direct on line start and the
starting torque is reduced to about 25 of the torque available at a DOL start This starting
method only works when the application is light loaded during the start If the motor is too heavily
27 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
loaded there will not be enough torque to accelerate the motor up to speed before switching over
to the delta position
LESSON 1 WIRING SYSTEM OF SINGLE PHASE DISTRIBUTION BOARD
Introduction
28 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
29 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
30 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
31 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 2 WIRING SYSTEM OF SINGLE PHASE LIGHTING CIRCUIT Introduction
Objectives
1 Identify component and the specification
2 Wire component according to the schematic diagram
3 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Wiring bay Perforated metal 180 cm x 180 cm 1
2 Cut out fuse 63 A 240 V 1
3 Neutral link 1
4 Single pole one way switch cw
switch box
5A 240Vac 4
5 single pole two way switch cw
switch box
5A 240Vac 2
6 RCCB In = 40 A Tripping current
100mA240 Vac 50 Hz
1
7 Main switch 32 A 240V 1
8 kWatthour meter 40 A 240 Vac 1
9 Single pole MCB 6A 240 Vac 1
10 Self tapping Wood screw As required
11 DIN rail 35 mm width As required
32 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
12 PVC trunking 50 mm x 50 mm As required
13 Terminal blocks 5 A As required
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
1 One way switch to control one lamp
2 One way switch to control two lamps
3 Two of two way switch to control one lamp
4 Two of single pole two way switch and one of an intermediate switch to control one
lamp
5 One unit of ceiling fan and fan regulator to be controlled by one way switch
4 Test the functionality of completed project
LESSON 3ndash WIRING SYSTEM OF SINGLE PHASE POWER CIRCUIT Introduction
33 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
34 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify types of component and its specification
2 Wire component according to the schematic diagram given
3 Test the functionality of the circuit dead circuit test life circuit test
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board Perforated Metal 1
2 kWh meter 240 V 40 A 1
3 Socket outlet 13A 240Vac 4
4 RCCB 40A Trip Amps
30mA240 Vac
1
5 3 pin socket 240Vac 13A 4
6 Single pole MCB 20A 240 V 2
7 DOL starter 1 kW 240Vac 2
8 1 phase induction motor 2Hp 240 Vac 1
9 Cooker control unit 4kW 240Vac 1
10 Water heater point 4kW 240 Vac 1
11 DIN rail 35 mm As required
12 PVC casing 20mm As required
13 Flexible wires 05 mm As required
14 Terminal block 10 A As required
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Wire two unit of 13 A socket outlet in radial circuit
3 Wire four units of 13 A socket outlet in ring circuit
4 Wire one unit DOL starter for air-conditioner point
5 Wire one unit of cooker control unit point
6 Wire one unit of water heater point
7 Test the functionality of each component by using mmeter or power supply whichever
applicable
8 Wire component according to circuit diagram
9 Test the functionality of completed project dead circuit test life circuit test
Note
35 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Ensure that the correct rating of protection device and size of wire used
LESSON 4ndash CONDUIT BENDING AND TRUNKING FABRICATION TECHNIQUE
Common fitting used in an industrial wiring
Cutting and threading the condute
36 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
37 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
38 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify conduit fitting and the specification
2 Measure and Cut steel conduit according to specified dimension
3 Bend and fabricate conduit at 45 90 according to layout diagram
4 Wire component according to the schematic diagram
5 Test the functionality of the circuit
39 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Conduit Bender Oslash 19 mm ( frac34 ldquo) 1
2 Measuring Tape 3 metre 1
3 Hacksaw frame and blade 30cm 1
4 Conduit cutter 1
5 Pipe Vise 1
6 Pipe Wrench 1
7 Ratchet Dies 20 mm 1
8 Metal trunking 50 mm x 50 mm 1
9 GI conduit 20mm 1
10 End box 20 mm 1
11 Flexible wires 05 mm As required
12 Connectors 5 A As required
13 Single core PVC ins Cable 25 mm 2 As required
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Wire two unit of 13 A socket outlet in radial circuit
3 Wire four unit of 13 A socket outlet in ring circuit
4 Wire one unit DOL starter for air-conditioner point
5 Wire one unit of cooker control unit point
6 Wire one unit of water heater point
7 Test the functionality of each component by using multimeter or power supply whichever
applicable
8 Wire component according to circuit diagram
9 Test the functionality of completed project
Note
Ensure that the rating of protection device and size of wire
K prior to 31 March
2004 (BS 7671)
(formerly)
bare conductor
sleeved at terminations (formerly)
40 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 5 ndashWIRING SYSTEM OF 1 Oslash LIGHTING AND POWER CIRCUIT
POWER CIRCUITSa Radial circuits
Radial circuits are arranged in the same way as item 1 above in lighting layouts in that each socket
outlet is supplied via the previous one
Points to note
1 The number of socket outlets complying with BS 1363 is unlimited for a floor area of up to 50m 2 if
the circuit protection is a 30 A or 32 A cartridge fuse or circuit breaker the cable being 4 mm PVC
copper or 25 mm2 mineral insulated (mi)
2 The number of socket outlets is unlimited for a floor area up to 20 m 2 with any type of circuit
protection of 20 A using 25 mm2 PVC copper cable or 15 mm2 mi
3 The total number of fused spurs is unlimited
b ring final circuits
These circuits are the same as radial circuits except that the final socket outlet is wired back to the
supply position In effect any outlet is supplied from two directions (Fig 152)
Points to note
1 Every twin-socket outlet counts as two single-socket outlets
2 The number of non-fused spurs must not exceed the total number of points on the ring Fig 158
shows seven points on the ring and five spurs
3 The fuse rating of a fused spur box must not exceed 13 A and the current rating of all points supplied
by the fused spur must not exceed 13 A
4 Non-fused spurs must supply no more than one single or one double socket on the ring Fig 158
shows seven points on the ring and five spurs rating of all points supplied by the fused spur must not
exceed 13 A or one stationary appliance
CapacityMain conductor size
copper (mm2)
Earth conductor
size (mm2)
Circuit breaker
capacity (A)
Up to 600 W 15 15 6
600ndash1200 W 1525 15 10
1200ndash1800 W 254 25 16
41 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Ring circuit
(floor area 100 m2)25 15 3032
A2 radial circuit
(floor area 75 m2)40 25 3032
A3 radial circuit
(floor area 50 m2)25 15 20
Air conditioner (15 tonne) 60 60 3032
Cooker 60 60 3032
Water heater 40 40 20
Objectives
1 Identify component and the specification
2 Wire component according to the schematic diagram
3 Test the functionality of the circuit
42 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board Perforated 1
2 Cut out fuse and neutral link 60A 240V 1each
3 kWh meter 240V 40A 1
4 Switched Socket outlet 13A 240Vac 4
5 Single pole two way switch cw switch
box
5A 240Vac 2
6 RCCB ELCB 63 A Tripping current 100mA
415 Vac
1
7 3 pin plug 240Vac 13A 4
8 Single pole MCB 20 A 2
9 Single pole MCB 6A 1
10 Single pole MCB 20A 2
11 DOL starter 240Vac 2
12 1 phase induction motor 2hp 240 Vac 1
13 Self tapping Wood screw As required
14 DIN rail Stainless steel allum35 mm As required
15 PVC pipe 20mm dia As required
16 End box 20 mm dia 4
17 Flexible wires 05 mm 2 As required
18 Connectors 5 A As required
Procedures
43 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
4 Test the functionality of completed project
LESSON 6 ndash WIRING SYSTEM OF 3 Oslash DISTRIBUTION BOARD
Introduction
44 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
45 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
46 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
47 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
48 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify each component and the specification
2 Wire component according to the schematic diagram given
3 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting Board 450 x 600 mm Perforated metal 1
2 5 pin round socket and plug 415V ac 32A 1
3 Cut out fuse 60 A 3
4 Neutral link 1
5 kWatt hour meter 415V 60A 1
6 ELCB RCCB 3P+N In=63A415 Vac I trip= 300mA 1
7 ELCB RCCB 3P+N In=63A415 Vac I trip= 30mA 1
8 Single pole MCB 6A 240 V 3
9 Single pole MCB 20A 240 V 3
10 DOL starter 20 A 240Vac 2
11 Socket outlet 15 A 240 Vac 1
12 Switched Socket outlet 13 A 240 Vac 3
13 Led indicating light 5A 240 Vac 3
14 Single pole 4 gang 1 way switch 5A 240 Vac 2
15 Single pole 2 way switch 5A 240 Vac 2
16 1 phase induction motor 1 kW 240Vac 1
17 Metal trunking 30 mm x30 mm As required
18 Self tapping Wood screw 4 mm x 20 mm As required
19 DIN rail 25 mm x 1mm
20 GI steel rigid conduit 20mm As required
21 Flexible conduit 20mm As required
22 End box 20 mm 4
23 Flexible wires 05 mm 2 As required
24 Single core PVC insulated wire 15 mm 2 As required
25 Single core PVC insulated wires 25 mm 2 As required
26 Terminal block 10 A As required
Procedures
49 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify each components and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
4 Test the functionality of completed project
1 dead circuit test
2 life circuit
Note Proper earthing should be made
50 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 7 ndash WIRING SYSTEM OF THREE PHASE LIGHTING AND POWER CIRCUIT
51 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
52 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify component and the specification
2 Wire component according to the schematic diagram
3 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting bay Board Perforated metal 180 cm x 180 cm 1
2 k Watt hour meter 415V 60A 1
3 MCCB 415V 60A
4 ELCB RCCB In=60A415 Vac I trip=30mA 1
5 5 pin round Socket and
plug
415Vac 32A 4
6 Single pole MCB 6A 1
7 Triple pole MCB 20A 2
8 Triple pole Main switch 60A 1
9 DOL starter 240Vac 2
10 3 phase induction motor 2hp 415 Vac 1
11 1 phase induction motor 1
12 Metal trunking 30 mm x30 mm As required
13 Self tapping Wood screw 4 mm x 20 mm As required
14 DIN rail 25 mm x 1mm
15 GI steel rigid conduit 20mm As required
16 Flexible conduit 20mm As required
17 End box 20 mm 4
18 Flexible wires 05 mm As required
19 Connectors 10 A As required
Procedures
1 Identify each components and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
4 Test the functionality of completed project
1 dead circuit 2 life circuit test
5 Record the current drawn by the load as connected in star and delta
Note Proper earthing should be made
53 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 8 INSPECTION AND TESTING OF ELECTRICAL INSTALLATION
On completion of a wiring installation a number of tests on the installation have to be conducted to
ascertain that the wiring circuits and connected appliances are safe for use Prior to carrying out the
tests an inspection has to be done The results of the inspectionsupervision and test have to be
presented in Form G (as in Appendix IV) and Form H (as in Appendix V)
To have the test certification as in Form H the following tests shall be conducted
i Continuity Test
ii Insulation Resistance Test
iii Polarity Test
iv Earth Electrode Resistance test and
v Residual Current Device Test
1 Continuity Test
There are 3 main types of continuity tests for the final circuits-
i Protection Conductor Continuity Test
ii Final Ring Circuit Conductor Continuity Test
iii Live and Neutral Conductor Continuity Test
a) Protection Conductor Continuity Test
bull To ascertain that all protection conductors are connected in the correct and effective manner
bull Test equipment ndash Multimeter (Ohm range) or Ohm meter
54 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
bull Test Method
1 1048766 Ensure that the main switch RCD and MCB are open circuited (switched off) and all loads
are disconnected
2 1048766 Connected the test leads as in the Figure 81 The meter reading shall be less than 1 Ω
55 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Final Ring Circuit Conductor Continuity Test
bull To ensure that all conductors around the ring circuit have continuity
bull Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
bull Test Method
1 1048766 Disconnect both the supply source live conductors from the MCB the neutral conductor
from the neutral terminals and the earth conductor from the earth terminal in the distribution
fuse box
2 1048766 Connect the test leads as in the Figure 82 (EE)
3 1048766 Repeat the procedure for (L-L) and (N-N)
4 1048766 The meter reading value shall be less than 1 ohm
56 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Live and Neutral Conductor Continuity Test
a To ensure that each conductor in the circuit has continuity
b Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
2 Test Method
1 1048766 Switch off the Main switch RCD and MCB
2 1048766 Disconnect all loads
3 1048766 Switch on all switches in the circuit
4 1048766 Disconnect the fusesfinal circuit breakers and close the circuit
5 1048766 Carry out the test as shown in Figure 83
6 1048766 The meter reading value shall be less than 1Ω
57 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
58 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
CONTINUITY TEST
Insulation Resistance Test
i Ensure that there is no leakage current between phase conductors phase and neutral conductors and
phase conductor and earth
ii Test the strength of the cable insulation
iii Test Equipment ndash Insulation Resistance Tester operating voltage is 250VDC or 500VDC
iv Test Method
1 1048766 Switch off main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
59 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
4 1048766 Carry out test as in the Table below
5 1048766 Meter reading value shall be less than 1 Megaohm
60 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
61 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Insulation resitance test
62 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
INSULATION RESISTANCE TEST BETWEEN CONDUCTORS AND OPPOSITE POLARITY
Polarity Testi Ensure that each fuse or single pole control and protection device is connected only in the phase
conductor
ii Intermediate contact of Edison screw lamp holder is connected to the phase conductor
iii Ensure that phase neutral and earth conductors at socket outlets are connected at the correct
terminals
iv Test Equipment ndash Multimeter (Ohm range) or Ohm meter
v Test Method
1 1048766 Switch off Main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in Figure 85
63 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
5 1048766 Test switches and single phase control devices at the phase conductors
6 1048766 Test socket outlet connection sources
7 1048766 Test Edison screw lamp holder connections
8 1048766 Meter reading value shall be less than 1 Ω
64 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Polarity test
65 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Earth Electrode Resistance Testi To test the earth electrode resistance
ii To ascertain the suitability of the location of the electrode
iii To ensure that the electrode is not buried within the resistance area of another electrode
iv Test equipment ndash Earth Resistance Tester
v Test method -
1 1048766 Terminal rsquoErsquo is connected to the electrode to be tested (green conductor)
2 1048766 Terminal lsquoPrsquo is connected to the potential spike (yellow conductor) at a distance of 10
meters from the earth electrode
3 1048766 Terminal lsquoCrsquo is connected to the current spike (red conductor) at a distance of 20 meters
from the earth electrode
Earth Electrode Resistance Measurement Method (Figure 86)
This test must be repeated at least three times to ensure that the reading is not affected by interacting
earthing regions
i Record the first reading (Z1) Example Z1 = 10 Ω
ii Move the voltage spike to a distance of 6 meters from the original position Record the second
reading (Z2 ) Example Z2 = 10 Ω
iii Move the voltage spike to a distance of 6 meters from the original position Record the third
reading (Z3) Example Z3 = 10 Ω
66 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Residual Current Device Testi Ensure that the residual current device (RCD) trips within the set time on the occurrence of current
leakage to earth
ii Test Equipment ndash RCD Tester RCCB Tester
iii Test Method 1
1 1048766 Use the Trip Test Button
2 1048766 Press the trip button found on the RCD to determine if it trips or otherwise This test would
not be able to determine the sensitivity of the RCD nor the time taken for it to trip
iv Test Method 2
i 1048766 Use a RCD Tester
ii This equipment is equipped with a 13A plug which can be connected to a 13A socket outlet
Select the RCD sensitivity to be the same as the sensitivity of the RCD to be tested to
determine if the RCD can trip The time to trip shall not exceed 40 mS
iii 1048766 Test method ndash
a) Position the selection switch in accordance with the sensitivity of the RCD used
Example 100 mA 01 A
b) Position the operations switch to lsquoNo Triprsquo (frac12 Rated mA = 50) connect the 3 pin plug to
the 13A socket outlet
67 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
c) Switch on the 13A socket outlet ndash ensure that the P-N and P-E lights light up
This shows that the polarity is correct (Note if both the lights as above do not light up the test cannot
be continued)
d) Press the test button ndash the reading shows less than 200 mS and simultaneously the lsquotestrsquo light lights
up and the P-N and P-E lights do not light up At that instant the RCD will not trip
e) Move the selection switch to 180o (+ve wave) ndash repeat steps (d) and (e) Move the operations
switch to lsquoTriprsquo (Rated mA = 100)
g) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200mS
h) Move the selection switch to 0o (-ve wave)
i) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
j) The above test is repeated until a near correct reading is obtained
k) Record the test results
l) Change the operations switch to lsquoFast Triprsquo and press the test button ndash RCD will trip within a
time not exceeding 40 millisecond
m) Repeat a number of times at 0o or 180o
On completion of a wiring installation a number of tests on the installation have to be conducted to
ascertain that the wiring circuits and connected appliances are safe for use Prior to carrying out the
tests an inspection has to be done the following tests shall be conducted
i Continuity Test
ii Insulation Resistance Test
iii Polarity Test
iv Earth Electrode Resistance test and
v Residual Current Device Test
821 Continuity Test
There are 3 main types of continuity tests for the final circuits-
i Protection Conductor Continuity Test
ii Final Ring Circuit Conductor Continuity Test
68 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
iii Live and Neutral Conductor Continuity Test
a) Protection Conductor Continuity Test
bull To ascertain that all protection conductors are connected in the correct and effective manner
bull Test equipment ndash Multimeter (Ohm range) or Ohm meter
bull Test Method
1 1048766 Ensure that the main switch RCD and MCB are open circuited (switched off) and all loads are
disconnected
2 1048766 Connected the test leads as in the Figure 81
3 1048766 The meter reading shall be less than 1 Ω
Final Ring Circuit Conductor Continuity Test
bull To ensure that all conductors around the ring circuit have continuity
bull Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
bull Test Method
1 1048766 Disconnect both the supply source live conductors from the MCB the neutral conductor
from the neutral terminals and the earth conductor from the earth terminal in the distribution
fuse box
2 1048766 Connect the test leads as in the Figure 82 (EE)
3 1048766 Repeat the procedure for (L-L) and (N-N)
4 1048766 The meter reading value shall be less than 1 ohm Figure 82 - Final Ring Circuit Conductor
Continuity Test Ohm Meter
Disconnect both the supply source cables from mcbfuse
Take readings at earth conductors of both sources and note resistance readings
Live and Neutral Conductor Continuity Test
1 To ensure that each conductor in the circuit has continuity
2 Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
3 Test Method
1 1048766 Switch off the Main switch RCD and MCB
2 1048766 Disconnect all loads
3 1048766 Switch on all switches in the circuit
4 1048766 Disconnect the fusesfinal circuit breakers and close the circuit
5 1048766 Carry out the test as shown in Figure 83
6 1048766 The meter reading value shall be less than 1 ohm Figure 83 - Live and Neutral
Conductor Continuity Test Ohm Meter
Insulation Resistance Test
69 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
i Ensure that there is no leakage current between phase conductors phase and neutral conductors and
phase conductor and earth
ii Test the strength of the cable insulation
iii Test Equipment ndash Insulation Resistance Tester Operating voltage is 250VDC or 500VDC
iv Test Method
1 1048766 Switch off main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in the Table below
5 1048766 Meter reading value shall be less than 1 Megaohm
Polarity Test
i Ensure that each fuse or single pole control and protection device is connected only in the phase
conductor
ii Intermediate contact of Edison screw lamp holder is connected to the phase conductor
iii Ensure that phase neutral and earth conductors at socket outlets are connected at the correct
terminals
iv Test Equipment ndash Multimeter (Ohm range) or Ohm meter
v Test Method
1 1048766 Switch off Main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in Figure 85
5 1048766 Test switches and single phase control devices at the phase conductors
6 1048766 Test socket outlet connection sources
7 1048766 Test Edison screw lamp holder connections
8 1048766 Meter reading value shall be less than 1 Ω
Earth Electrode Resistance Test
i To test the earth electrode resistance
70 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
ii To ascertain the suitability of the location of the electrode
iii To ensure that the electrode is not buried within the resistance area of another electrode
iv Test equipment ndash Earth Resistance Tester
v Test method -
1 1048766 Terminal rsquoErsquo is connected to the electrode to be tested (green conductor)
2 1048766 Terminal lsquoPrsquo is connected to the potential spike (yellow conductor) at a distance of 10
meters from the earth electrode
3 1048766 Terminal lsquoCrsquo is connected to the current spike (red conductor) at a distance of 20 meters
from the earth electrode E P C Electrode 10 meter 10 meter
Figure 86 ndash Earth Electrode Resistance Measurement Test Equipment
Earth Electrode Resistance Measurement Method (Figure 86)
This test must be repeated at least three times to ensure that the reading is not affected by interacting
earthing regions
i Record the first reading (Z1) Example Z1 = 10 Ω
ii Move the voltage spike to a distance of 6 meters from the original position Record the second
reading (Z2) Example Z2 = 10 Ω
iii Move the voltage spike to a distance of 6 meters from the original position Record the third
reading (Z3)
Example Z3 = 10 Ω
Residual Current Device Test
71 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
i Ensure that the residual current device (RCD) trips within the set time on the occurrence of current
leakage to earth
ii Test Equipment ndash RCD Tester RCCB Tester
iii Test Method 1
1 1048766 Use the Trip Test Button
2 1048766 Press the trip button found on the RCD to determine if it trips or otherwise This test would
not be able to determine the sensitivity of the RCD nor the time taken for it to trip
iv Test Method 2
1048766 Use a RCD Tester
This equipment is equipped with a 13A plug which can be connected to a 13A socket outlet Select the
RCD sensitivity to be the same as the sensitivity of the RCD to be tested to determine if the RCD can
trip The time to trip shall not exceed 40 mS
1048766 Test method ndash
a) Position the selection switch in accordance with the sensitivity of the RCD used
Example 100 mA 01 A
b) Position the operations switch to lsquoNo Triprsquo (frac12 Rated mA = 50) connect the 3 pin plug to
the 13A socket outlet
c) Switch on the 13A socket outlet ndash ensure that the P-N and P-E lights light up This shows that
the polarity is correct (Note if both the lights as above do not light up the test cannot be
continued)
d) Press the test button ndash the reading shows less than 200 millisecond and simultaneously the
lsquotestrsquo light lights up and the P-N and P-E lights do not light up At that instant the RCD will
not trip
e) Move the selection switch to 180o (+ve wave) ndash repeat steps (d) and (e) = 100)
f) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
g) Move the selection switch to 0o (-ve wave)
h) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
i) The above test is repeated until a near correct reading is obtained
j) Record the test results
k) Change the operations switch to lsquoFast Triprsquo and press the test button ndash RCD will trip within a
time not exceeding 40 mS
l) Repeat a number of times at 0o or 180o
72 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 9 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (DC)
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
73 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Start stop button 240Vac 5A 2
9 Filament lamp (Bulb ) 240Vac 40W 3
10 Overload Relay 415V 20A 3
11 Three phase induction motor 5 hp 3
12 Single phase step down transformer 2500VA 1
13 Single core PVC insulated Cable 1mm 2 As required
14 Single core PVC insulated Cable 25mm 2 As required
15 DIN rail 35 mm As required
16 PVC type Cable tray 50 mm x 50 mm As required
17 Cable ties 4 ldquo As required
18 Flexible wires 05 mm As required
19 PVC Connectors 5 A amp 20 A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the schematic
diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a optional exercise
i Simple DOL starter
ii Forward reverse DOL starter
iii Forward Reverse Dahlander motor
iv Three motors operated in sequence by DOL starter operated by manual push
button or time delay relay
74 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
a One loop per-cycle
b Continuous operation in a loop
c optional circuit design to represent the same task
v Only one out of three motors to be operated at a time (quiz)
4 Test the functionality of completed project
LESSON 10 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (AC)
75 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 1
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Lamp point 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
76 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
11 Overload Relay 415V 20A 3
12 Three phase induction
motor
5 hp 3
13 Single core PVC insulated
Cable
1mm 2 As required
14 Single core PVC insulated
Cable
25mm 2 As required
15 DIN rail 35 mm As required
16 PVC type Cable tray 50 mm x 50 mm As required
17 Cable ties 4 ldquo As required
18 Flexible wires 05 mm As required
19 PVC Connectors 5 A amp 20 A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the
schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram optional exercise
4 Simple DOL starter
5 Forward reverse DOL starter
6 Test the functionality of completed project
77 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 1
78 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
cm
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Indicating light 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
11 Overload Relay 415V 20A 3
12 Three phase induction motor 5 hp 3
13 Single phase step down
transformer
2500VA 1
14 Single core PVC insulated
Cable
1mm 2 As required
15 Single core PVC insulated
Cable
25mm 2 As required
16 DIN rail 35 mm As required
17 PVC type Cable tray 50 mm x 50 mm As required
18 Cable ties 4 ldquo As required
19 Flexible wires 05 mm As required
20 PVC Connectors 5 A amp 20 A 240 V As required
21 Single pole MCB 6A 240 V 1
22 Single pole MCB 2A 240 V 1
23 Triple pole MCB 20A 415 V 1
24 Mounting board 30 cm x 40 cm x 3
cm
1
25 Relay cw 11 pin socket 10 A 240 Vac 2
26 Time delay relay 10 A 240 Vac 3
27 Triple pole Contactor 20A 240Vac 3
28 Batten type Lamp holder 240Vac 10 A 3
29 Start stop button 240Vac 10A 2
30 Indicating light (Bulb ) 240Vac 25W 3
31 Overload Relay 415V 20A 1
32 Three phase dahlander type
induction motor
5 hp 1
33 Single phase step down
transformer
24024Vac
2500VA
1
79 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
34 Single core PVC insulated
Cable
1mm 2 As required
35 Single core PVC insulated
Cable
25mm 2 As required
36 DIN rail 35 mm As required
37 PVC type Cable tray 50 mm x 50 mm As required
38 Cable ties 4 ldquo As required
39 Flexible wires 075 mm As required
40 PVC Connectors 5 A amp 20 A 240 V As required
41 Terminal block 20A 240Vac As required
Procedures
5 Identify each component according to specification and quantity required from the schematic
diagram attached
6 Test the functionality of each component by using multi-meter or power supply whichever
applicable
7 Wire component according to circuit diagram
8 Three motors operated in sequence by DOL starter operated by manual push button or time
delay relay
a One loop per-cycle
b Continuous operation in a loop
c optional circuit design to represent the same task
d Only one out of three motors to be operated at a time (quiz)
9 Test the functionality of completed project
80 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
BASIC DESIGN INDUSTRIAL MOTOR CONTROL (SEQUENCE CONTROL)
THREE PHASE INDUCTION MOTOR OPERATED IN SEQUENCE BY DIRECT ON LINE
STARTER
LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
81 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
82 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Lcd lamp indicator 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
11 Overload Relay 415V 20A 3
12 Three phase induction motor 5 hp 3
13 Single phase step down transformer 2500VA 1
14 Single core PVC insulated Cable 1mm 2 As required
15 Single core PVC insulated Cable 25mm 2 As required
16 DIN rail 35 mm As required
17 PVC type Cable tray 50 mm x 50 mm As required
18 Cable ties 4 ldquo As required
19 Flexible wires 1 mm Oslash As required
20 PVC Terminal block 10A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the schematic
diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a optional exercise
i Forward Reverse dahlander motor
4 Test the functionality of completed project
83 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
THREE PHASE DAHLANDER TYPE INDUCTION MOTOR OPERATED FORWARD AND
REVERSE OPERATION BY DIRECT ON LINE STARTER
84 ndash 99EASYTECH ENTERPRISE
LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
Introduction
If a motors windings are connected in the star configuration any two phases will be in series across
the supply and hence the line current will be smaller(by 577) than if the windings were connected in
the delta arrangement
Hence larger-type motors with heavy starting currents are first connected in star and then when the
starting currents fall in delta This of course means that all six of the ends of the windings must be
brought to terminations outside the casing (Fig 833)
EZTECH
EZTECH ELECTRICAL INSTALLATION GUIDE
The automatic version of this starter incorporates a timing relay which automatically changes the
connections from star to delta Figs 834 and 835 show the wiring and schematic diagrams for a star
delta starter
Objectives
1 Identify component and the specification
2 Design forward reverse star delta starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
2 ndash 99EASYTECH ENTERPRISE
REV -C
LEGENDMCCB Moulded Case Circuit BreakerTOR Thermal Over Load RelayFOW-C Mains Forward ContactorREV-C Mains Reverse ContactorDC Delta ContactorSC Star ContactorS-SW Mains Selector Switch
SC
V2
W2
U2
DC
V1
W1
U1
TOR
TOR
FOW-C
30A MCCB
TOR
MAIN CIRCUIT FORWARD REVERSE STAR DELTA
RYBN S
-SW
3 PHASEINDUCTION MOTOR
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Relay 10 A 240V 3
5 Triple pole Contactor
6 cw NO NC auxiliary contact
240Vac 20 A 4
7 Overload Relay 415 V 1
8 LED indicator 240vac 5 A 4
9 Start stop button 240Vac 5A 2
10 DIN rail 35 mm As required
11 Flexible wires 1 mm As required
12 Single core PVC insulated
wire
25 mm As required
13 Terminal block 20 A As required
14 Squirrel cage motor 5kW 1
15 5 pin plug and socket 415V 20A 1
16 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
3 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
a Manual star delta
b Manual Forward reverse star delta starter
c Automatic star delta starter
d Automatic Forward reverse star delta starter
4 Test the functionality of completed project
4 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
Objectives
1 Identify component and the specification
2 Design auto transformer starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
5 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Autotransformer starter is used to start a 3 phase induction motor that has a rating between 10 to 15 hp
6 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Autotransformer set 10Kw 415 V 50 Hz 1
5 Triple pole Contactor 240Vac 4
6 Batten type Lamp holder 240 Vac 105 A 4
7 Start stop button 240Vac 10A 4
8 Filament lamp (Bulb ) 240Vac 40W 4
9 DIN rail 35 mm As required
10 Flexible wires 1 mm As required
7 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
11 Single core PVC insulated
wire
25 mm As required
12 Terminal block 20 A As required
13 Squirrel cage motor 10kW 1
14 5 pin plug and socket 415V 20A 1
15 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a open transient autotransformer starter
b close transient autotransformer starter
c Forward reverse autotransformer starter
4 Test the functionality of completed project
8 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
Objectives
1 Identify component and the specification
2 Design rotor resistance starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
9 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Rotor Resistor set 10kW 1
5 Triple pole Contactor 240Vac 20A 4
6 Indicating light 240vac 5 A 4
7 Start stop push button 240Vac 5A 4
8 DIN rail 35 mm As required
9 Flexible wires 1 mm 2 As required
10 Single core PVC insulated wire 25 mm 2 As required
11 Terminal block 20 A As required
12 Slip Ring motor 10kW 1
13 5 pin round 3 phase socket 415V 20A 1
14 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
10 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
4 Test the functionality of completed project
a Dead circuit test b Life circuit test
5 Measure starting and running Amps
LESSON 16
TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
An installation in general will suffer damage
Damage usually occurs on the electric motor control as follows
1 Damage to the main circuit
2 Damage to the control circuit
The cause of the damage
i Overcurrent overload short circuit
ii Leakage current to ground
iii Equipment malfunction
iv The main control circuit
a Trip of main circuit protection devices fire
b Defect of motor terminal such as short circuit fire loose
v The control circuit is not functioning -
a contactor relay relay time overload relay does not work damaged burned
b Loose cable connection disconnected
Detecting and Repairing Damage
Examples of damage are as follows
i Motor does not work
ii Motor function and overload relay trips
iii Motor function but only partially functional control circuit
Methods of detecting damage
Among the known methods necessary to detect damage are as follows
1 Turn off the electricity at the main switch (main switch) in order to avoid any danger during the
work carried out to detect damage
2 Check all the protective gear that controls the motor control main circuit
11 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
3 Make sure the damage function control circuit
4 Check the control circuit according to the schematic circuit diagram of the motor control
5 Check the operation of the control circuit
Note
Use wiring that has been installed on the SYSTEM OF MOTOR CONTROL BOARD by Forward
Reverse control circuit for Star Delta to test and look for damage
SELF-ASSESSMENT QUESTIONS
1 (a) Explain what is meant by the term lsquoback emfrsquo in a motor
(b) Outline the basic differences between series shunt and compound wound dc motors
2 (a) With the aid of diagrams explain how the speed of series shunt and compound-wound motors
may be controlled
(b) A 440V dc shunt-wound motor has a field resistance of 200R and an armature resistance of 06 R
When its speed is 20 rev d second the current drawn from the supply is 122A Calculate its back
emf at this speed If the speed were decreased to 19 revssecond the field flux remaining unchanged
calculate the new back emf and the new armature current
3 A load of 64 kW at 240 V is supplied from the terminals of a shunt-wound dc generator The field
resistance is 180 A Calculate the armature current
4 (a) Explain with the aid of a diagram how a rotating magnetic field may be
(b) What is meant by lsquosynchronous speedrsquo
Calculate the synchronous obtained speed of a 12 pole motor if the supply frequency is 50Hz
5 (a) Explain the action of a synchronous motor
(b) What methods are available to start a synchronous motor Explain with diagrams
6 (a) Explain the action of a cage induction motor
(b) What is meant by the term lsquosliprsquo
Calculate the percentage slip of a six pole induction motor running at 162 revssecond from a 50 Hz
supply
7 Describe with sketches three different ways of starting a single-phase induction motor
12 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
8 Explain with the aid of a sketch the action of a three-phase DOL starter
What are dashpots used for How are remote start and stop buttons connected
9 A I0 kW 240V 50Hz single-phase cage rotor induction motor is 85efficient and has a PF of 068
lagging Calculate the motor current and the value of capacitor required to raise the PF to 093
lagging
10 Calculate the torque developed by an 18 kW four-pole induction motor run at 35 slip from a
50Hz supply
APPENDIX 1
13 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 11
14 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 111
Attachment Reference
httpswwwtlc-directcoukBook621htm
httpwwwstgovmyindexphpms
15 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 OFF State All Contactors are open
2 Star State The Main [KM3] and the Star [KM1] contactors are closed and the delta [KM2]
contactor is open The motor is connected in star and will produce one third of DOL torque at one
third of DOL current
3 Open State This type of operation is called open transition switching because there is an
open state between the star state and the delta state The Main contractor is closed and the Delta
and Star contactors are open There is voltage on one end of the motor windings but the other end
is open so no current can flow The motor has a spinning rotor and behaves like a generator
4 Delta State The Main and the Delta contactors are closed The Star contactor is open The
motor is connected to full line voltage and full power and torque are available
(2) Closed Transition StarDelta Starter
There is a technique to reduce the magnitude of the switching transients This requires the use of a
fourth contactor and a set of three resistors The resistors must be sized such that considerable
current is able to flow in the motor windings while they are in circuit
The auxiliary contactor and resistors are connected across the delta contactor In operation just
before the star contactor opens the auxiliary contactor closes resulting in current flow via the
resistors into the star connection Once the star contactor opens current is able to flow round
through the motor windings to the supply via the resistors These resistors are then shorted by the
delta contactor If the resistance of the resistors is too high they will not swamp the voltage
generated by the motor and will serve no purpose
In closed transition the power is maintained to the motor at all time This is achieved by
introducing resistors to take up the current flow during the winding changeover A fourth
contractor is required to place the resistor in circuit before opening the star contactor and then
removing the resistors once the delta contactor is closed These resistors need to be sized to carry
the motor current In addition to requiring more switching devices the control circuit is more
complicated due to the need to carry out resistor switching
In Close transition there are Four states
1 OFF State All Contactors are open
2 Star State The Main [KM3] and the Star [KM1] contactors are closed and the delta [KM2]
contactor is open The motor is connected in star and will produce one third of DOL torque at one
third of DOL current
Star Transition State The motor is connected in star and the resistors are connected across the
delta contactor via the aux [KM4] contactor
24 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Closed Transition State The Main [KM3] contactor is closed and the Delta [KM2] and Star
[KM1] contactors are open Current flows through the motor windings and the transition resistors
via KM4
Delta State The Main and the Delta contactors are closed The transition resistors are shorted out
The Star contactor is open The motor is connected to full line voltage and full power and torque
are available
Effect of Transient in Starter (Open Transient starter)
It is Important the pause between star contactor switch off and Delta contactor switch is on correct
This is because Star contactor must be reliably disconnected before Delta contactor is activated It
is also important that the switch over pause is not too long
For 415v Star Connection voltage is effectively reduced to 58 or 240v The equivalent of 33
that is obtained with Direct Online (DOL) starting
If Star connection has sufficient torque to run up to 75 or 80 of full load speed then the motor
can be connected in Delta mode
When connected to Delta configuration the phase voltage increases by a ratio of V3 or 173 The
phase currents increase by the same ratio The line current increases three times its value in star
connection
During transition period of switchover the motor must be free running with little deceleration
While this is happening ldquoCoastingrdquo it may generate a voltage of its own and on connection to the
supply this voltage can randomly add to or subtract from the applied line voltage This is known as
transient current Only lasting a few milliseconds it causes voltage surges and spikes Known as
a changeover transient
Size of each part of Star-Delta starter
(1) Size of Over Load Relay
For a star-delta starter there is a possibility to place the overload protection in two positions in the
line or in the windings
Overload Relay in Line
In the line is the same as just putting the overload before the motor as with a DOL starter
The rating of Overload (In Line) = FLC of Motor
Disadvantage If the overload is set to FLC then it is not protecting the motor while it is in delta
(setting is x1732 too high)
Overload Relay in Winding
25 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
In the windings means that the overload is placed after the point where the wiring to the contactors
are split into main and delta The overload then always measures the current inside the windings
The setting of Overload Relay (In Winding) =058 X FLC (line current)
Disadvantage We must use separate short circuit and overload protections
(2) Size of Main and Delta Contractor
1 There are two contactors that are close during run often referred to as the main contractor and
the delta contactor These are AC3 rated at 58 of the current rating of the motor
Size of Main Contactor= IFL x 058
(3) Size of Star Contractor
The third contactor is the star contactor and that only carries star current while the motor is
connected in star The current in star is 1 radic3= (58) of the current in delta so this contactor can
be AC3 rated at one third (33) of the motor rating
Size of Star Contactor= IFL x 033
Motor Starting Characteristics of Star-Delta Starter
Available starting current 33 Full Load Current
Peak starting current 13 to 26 Full Load Current
Peak starting torque 33 Full Load Torque
Advantages of Star-Delta starter
The operation of the star-delta method is simple and rugged
It is relatively cheap compared to other reduced voltage methods
Good TorqueCurrent Performance
It draws 2 times starting current of the full load ampere of the motor connected
Disadvantages of Star-Delta starter
Low Starting Torque (Torque = (Square of Voltage) is also reduce)
Break In Supply ndash Possible Transients
Six Terminal Motor Required (Delta Connected)
It requires 2 set of cables from starter to motor
It provides only 33 starting torque and if the load connected to the subject motor requires higher
starting torque at the time of starting than very heavy transients and stresses are produced while
changing from star to delta connections and because of these transients and stresses many
electrical and mechanical break-down occurs
26 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
In this method of starting initially motor is connected in star and then after change over the motor
is connected in delta The delta of motor is formed in starter and not on motor terminals
High transmission and current peaks When starting up pumps and fans for example the load
torque is low at the beginning of the start and increases with the square of the speed When
reaching approx 80-85 of the motor rated speed the load torque is equal to the motor torque and
the acceleration ceases To reach the rated speed a switch over to delta position is necessary and
this will very often result in high transmission and current peaks In some cases the current peak
can reach a value that is even bigger than for a DOL start
Applications with a load torque higher than 50 of the motor rated torque will not be able to start
using the start-delta starter
Low Starting Torque The star-delta (wye-delta) starting method controls whether the lead
connections from the motor are configured in a star or delta electrical connection The initial
connection should be in the star pattern that results in a reduction of the line voltage by a factor of
1radic3 (577) to the motor and the current is reduced to 13 of the current at full voltage but the
starting torque is also reduced 13 to 15 of the DOL starting torque
The transition from star to delta transition usually occurs once nominal speed is reached but is
sometimes performed as low as 50 of nominal speed which make transient Sparks
Features of star-delta starting
1 For low- to high-power three-phase motors
2 Reduced starting current
3 Six connection cables
4 Reduced starting torque
5 Current peak on changeover from star to delta
6 Mechanical load on changeover from star to delta
Application of Star-Delta Starter
The star-delta method is usually only applied to low to medium voltage and light starting
Torque motors
The received starting current is about 30 of the starting current during direct on line start and the
starting torque is reduced to about 25 of the torque available at a DOL start This starting
method only works when the application is light loaded during the start If the motor is too heavily
27 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
loaded there will not be enough torque to accelerate the motor up to speed before switching over
to the delta position
LESSON 1 WIRING SYSTEM OF SINGLE PHASE DISTRIBUTION BOARD
Introduction
28 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
29 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
30 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
31 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 2 WIRING SYSTEM OF SINGLE PHASE LIGHTING CIRCUIT Introduction
Objectives
1 Identify component and the specification
2 Wire component according to the schematic diagram
3 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Wiring bay Perforated metal 180 cm x 180 cm 1
2 Cut out fuse 63 A 240 V 1
3 Neutral link 1
4 Single pole one way switch cw
switch box
5A 240Vac 4
5 single pole two way switch cw
switch box
5A 240Vac 2
6 RCCB In = 40 A Tripping current
100mA240 Vac 50 Hz
1
7 Main switch 32 A 240V 1
8 kWatthour meter 40 A 240 Vac 1
9 Single pole MCB 6A 240 Vac 1
10 Self tapping Wood screw As required
11 DIN rail 35 mm width As required
32 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
12 PVC trunking 50 mm x 50 mm As required
13 Terminal blocks 5 A As required
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
1 One way switch to control one lamp
2 One way switch to control two lamps
3 Two of two way switch to control one lamp
4 Two of single pole two way switch and one of an intermediate switch to control one
lamp
5 One unit of ceiling fan and fan regulator to be controlled by one way switch
4 Test the functionality of completed project
LESSON 3ndash WIRING SYSTEM OF SINGLE PHASE POWER CIRCUIT Introduction
33 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
34 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify types of component and its specification
2 Wire component according to the schematic diagram given
3 Test the functionality of the circuit dead circuit test life circuit test
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board Perforated Metal 1
2 kWh meter 240 V 40 A 1
3 Socket outlet 13A 240Vac 4
4 RCCB 40A Trip Amps
30mA240 Vac
1
5 3 pin socket 240Vac 13A 4
6 Single pole MCB 20A 240 V 2
7 DOL starter 1 kW 240Vac 2
8 1 phase induction motor 2Hp 240 Vac 1
9 Cooker control unit 4kW 240Vac 1
10 Water heater point 4kW 240 Vac 1
11 DIN rail 35 mm As required
12 PVC casing 20mm As required
13 Flexible wires 05 mm As required
14 Terminal block 10 A As required
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Wire two unit of 13 A socket outlet in radial circuit
3 Wire four units of 13 A socket outlet in ring circuit
4 Wire one unit DOL starter for air-conditioner point
5 Wire one unit of cooker control unit point
6 Wire one unit of water heater point
7 Test the functionality of each component by using mmeter or power supply whichever
applicable
8 Wire component according to circuit diagram
9 Test the functionality of completed project dead circuit test life circuit test
Note
35 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Ensure that the correct rating of protection device and size of wire used
LESSON 4ndash CONDUIT BENDING AND TRUNKING FABRICATION TECHNIQUE
Common fitting used in an industrial wiring
Cutting and threading the condute
36 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
37 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
38 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify conduit fitting and the specification
2 Measure and Cut steel conduit according to specified dimension
3 Bend and fabricate conduit at 45 90 according to layout diagram
4 Wire component according to the schematic diagram
5 Test the functionality of the circuit
39 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Conduit Bender Oslash 19 mm ( frac34 ldquo) 1
2 Measuring Tape 3 metre 1
3 Hacksaw frame and blade 30cm 1
4 Conduit cutter 1
5 Pipe Vise 1
6 Pipe Wrench 1
7 Ratchet Dies 20 mm 1
8 Metal trunking 50 mm x 50 mm 1
9 GI conduit 20mm 1
10 End box 20 mm 1
11 Flexible wires 05 mm As required
12 Connectors 5 A As required
13 Single core PVC ins Cable 25 mm 2 As required
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Wire two unit of 13 A socket outlet in radial circuit
3 Wire four unit of 13 A socket outlet in ring circuit
4 Wire one unit DOL starter for air-conditioner point
5 Wire one unit of cooker control unit point
6 Wire one unit of water heater point
7 Test the functionality of each component by using multimeter or power supply whichever
applicable
8 Wire component according to circuit diagram
9 Test the functionality of completed project
Note
Ensure that the rating of protection device and size of wire
K prior to 31 March
2004 (BS 7671)
(formerly)
bare conductor
sleeved at terminations (formerly)
40 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 5 ndashWIRING SYSTEM OF 1 Oslash LIGHTING AND POWER CIRCUIT
POWER CIRCUITSa Radial circuits
Radial circuits are arranged in the same way as item 1 above in lighting layouts in that each socket
outlet is supplied via the previous one
Points to note
1 The number of socket outlets complying with BS 1363 is unlimited for a floor area of up to 50m 2 if
the circuit protection is a 30 A or 32 A cartridge fuse or circuit breaker the cable being 4 mm PVC
copper or 25 mm2 mineral insulated (mi)
2 The number of socket outlets is unlimited for a floor area up to 20 m 2 with any type of circuit
protection of 20 A using 25 mm2 PVC copper cable or 15 mm2 mi
3 The total number of fused spurs is unlimited
b ring final circuits
These circuits are the same as radial circuits except that the final socket outlet is wired back to the
supply position In effect any outlet is supplied from two directions (Fig 152)
Points to note
1 Every twin-socket outlet counts as two single-socket outlets
2 The number of non-fused spurs must not exceed the total number of points on the ring Fig 158
shows seven points on the ring and five spurs
3 The fuse rating of a fused spur box must not exceed 13 A and the current rating of all points supplied
by the fused spur must not exceed 13 A
4 Non-fused spurs must supply no more than one single or one double socket on the ring Fig 158
shows seven points on the ring and five spurs rating of all points supplied by the fused spur must not
exceed 13 A or one stationary appliance
CapacityMain conductor size
copper (mm2)
Earth conductor
size (mm2)
Circuit breaker
capacity (A)
Up to 600 W 15 15 6
600ndash1200 W 1525 15 10
1200ndash1800 W 254 25 16
41 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Ring circuit
(floor area 100 m2)25 15 3032
A2 radial circuit
(floor area 75 m2)40 25 3032
A3 radial circuit
(floor area 50 m2)25 15 20
Air conditioner (15 tonne) 60 60 3032
Cooker 60 60 3032
Water heater 40 40 20
Objectives
1 Identify component and the specification
2 Wire component according to the schematic diagram
3 Test the functionality of the circuit
42 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board Perforated 1
2 Cut out fuse and neutral link 60A 240V 1each
3 kWh meter 240V 40A 1
4 Switched Socket outlet 13A 240Vac 4
5 Single pole two way switch cw switch
box
5A 240Vac 2
6 RCCB ELCB 63 A Tripping current 100mA
415 Vac
1
7 3 pin plug 240Vac 13A 4
8 Single pole MCB 20 A 2
9 Single pole MCB 6A 1
10 Single pole MCB 20A 2
11 DOL starter 240Vac 2
12 1 phase induction motor 2hp 240 Vac 1
13 Self tapping Wood screw As required
14 DIN rail Stainless steel allum35 mm As required
15 PVC pipe 20mm dia As required
16 End box 20 mm dia 4
17 Flexible wires 05 mm 2 As required
18 Connectors 5 A As required
Procedures
43 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
4 Test the functionality of completed project
LESSON 6 ndash WIRING SYSTEM OF 3 Oslash DISTRIBUTION BOARD
Introduction
44 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
45 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
46 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
47 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
48 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify each component and the specification
2 Wire component according to the schematic diagram given
3 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting Board 450 x 600 mm Perforated metal 1
2 5 pin round socket and plug 415V ac 32A 1
3 Cut out fuse 60 A 3
4 Neutral link 1
5 kWatt hour meter 415V 60A 1
6 ELCB RCCB 3P+N In=63A415 Vac I trip= 300mA 1
7 ELCB RCCB 3P+N In=63A415 Vac I trip= 30mA 1
8 Single pole MCB 6A 240 V 3
9 Single pole MCB 20A 240 V 3
10 DOL starter 20 A 240Vac 2
11 Socket outlet 15 A 240 Vac 1
12 Switched Socket outlet 13 A 240 Vac 3
13 Led indicating light 5A 240 Vac 3
14 Single pole 4 gang 1 way switch 5A 240 Vac 2
15 Single pole 2 way switch 5A 240 Vac 2
16 1 phase induction motor 1 kW 240Vac 1
17 Metal trunking 30 mm x30 mm As required
18 Self tapping Wood screw 4 mm x 20 mm As required
19 DIN rail 25 mm x 1mm
20 GI steel rigid conduit 20mm As required
21 Flexible conduit 20mm As required
22 End box 20 mm 4
23 Flexible wires 05 mm 2 As required
24 Single core PVC insulated wire 15 mm 2 As required
25 Single core PVC insulated wires 25 mm 2 As required
26 Terminal block 10 A As required
Procedures
49 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify each components and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
4 Test the functionality of completed project
1 dead circuit test
2 life circuit
Note Proper earthing should be made
50 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 7 ndash WIRING SYSTEM OF THREE PHASE LIGHTING AND POWER CIRCUIT
51 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
52 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify component and the specification
2 Wire component according to the schematic diagram
3 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting bay Board Perforated metal 180 cm x 180 cm 1
2 k Watt hour meter 415V 60A 1
3 MCCB 415V 60A
4 ELCB RCCB In=60A415 Vac I trip=30mA 1
5 5 pin round Socket and
plug
415Vac 32A 4
6 Single pole MCB 6A 1
7 Triple pole MCB 20A 2
8 Triple pole Main switch 60A 1
9 DOL starter 240Vac 2
10 3 phase induction motor 2hp 415 Vac 1
11 1 phase induction motor 1
12 Metal trunking 30 mm x30 mm As required
13 Self tapping Wood screw 4 mm x 20 mm As required
14 DIN rail 25 mm x 1mm
15 GI steel rigid conduit 20mm As required
16 Flexible conduit 20mm As required
17 End box 20 mm 4
18 Flexible wires 05 mm As required
19 Connectors 10 A As required
Procedures
1 Identify each components and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
4 Test the functionality of completed project
1 dead circuit 2 life circuit test
5 Record the current drawn by the load as connected in star and delta
Note Proper earthing should be made
53 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 8 INSPECTION AND TESTING OF ELECTRICAL INSTALLATION
On completion of a wiring installation a number of tests on the installation have to be conducted to
ascertain that the wiring circuits and connected appliances are safe for use Prior to carrying out the
tests an inspection has to be done The results of the inspectionsupervision and test have to be
presented in Form G (as in Appendix IV) and Form H (as in Appendix V)
To have the test certification as in Form H the following tests shall be conducted
i Continuity Test
ii Insulation Resistance Test
iii Polarity Test
iv Earth Electrode Resistance test and
v Residual Current Device Test
1 Continuity Test
There are 3 main types of continuity tests for the final circuits-
i Protection Conductor Continuity Test
ii Final Ring Circuit Conductor Continuity Test
iii Live and Neutral Conductor Continuity Test
a) Protection Conductor Continuity Test
bull To ascertain that all protection conductors are connected in the correct and effective manner
bull Test equipment ndash Multimeter (Ohm range) or Ohm meter
54 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
bull Test Method
1 1048766 Ensure that the main switch RCD and MCB are open circuited (switched off) and all loads
are disconnected
2 1048766 Connected the test leads as in the Figure 81 The meter reading shall be less than 1 Ω
55 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Final Ring Circuit Conductor Continuity Test
bull To ensure that all conductors around the ring circuit have continuity
bull Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
bull Test Method
1 1048766 Disconnect both the supply source live conductors from the MCB the neutral conductor
from the neutral terminals and the earth conductor from the earth terminal in the distribution
fuse box
2 1048766 Connect the test leads as in the Figure 82 (EE)
3 1048766 Repeat the procedure for (L-L) and (N-N)
4 1048766 The meter reading value shall be less than 1 ohm
56 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Live and Neutral Conductor Continuity Test
a To ensure that each conductor in the circuit has continuity
b Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
2 Test Method
1 1048766 Switch off the Main switch RCD and MCB
2 1048766 Disconnect all loads
3 1048766 Switch on all switches in the circuit
4 1048766 Disconnect the fusesfinal circuit breakers and close the circuit
5 1048766 Carry out the test as shown in Figure 83
6 1048766 The meter reading value shall be less than 1Ω
57 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
58 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
CONTINUITY TEST
Insulation Resistance Test
i Ensure that there is no leakage current between phase conductors phase and neutral conductors and
phase conductor and earth
ii Test the strength of the cable insulation
iii Test Equipment ndash Insulation Resistance Tester operating voltage is 250VDC or 500VDC
iv Test Method
1 1048766 Switch off main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
59 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
4 1048766 Carry out test as in the Table below
5 1048766 Meter reading value shall be less than 1 Megaohm
60 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
61 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Insulation resitance test
62 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
INSULATION RESISTANCE TEST BETWEEN CONDUCTORS AND OPPOSITE POLARITY
Polarity Testi Ensure that each fuse or single pole control and protection device is connected only in the phase
conductor
ii Intermediate contact of Edison screw lamp holder is connected to the phase conductor
iii Ensure that phase neutral and earth conductors at socket outlets are connected at the correct
terminals
iv Test Equipment ndash Multimeter (Ohm range) or Ohm meter
v Test Method
1 1048766 Switch off Main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in Figure 85
63 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
5 1048766 Test switches and single phase control devices at the phase conductors
6 1048766 Test socket outlet connection sources
7 1048766 Test Edison screw lamp holder connections
8 1048766 Meter reading value shall be less than 1 Ω
64 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Polarity test
65 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Earth Electrode Resistance Testi To test the earth electrode resistance
ii To ascertain the suitability of the location of the electrode
iii To ensure that the electrode is not buried within the resistance area of another electrode
iv Test equipment ndash Earth Resistance Tester
v Test method -
1 1048766 Terminal rsquoErsquo is connected to the electrode to be tested (green conductor)
2 1048766 Terminal lsquoPrsquo is connected to the potential spike (yellow conductor) at a distance of 10
meters from the earth electrode
3 1048766 Terminal lsquoCrsquo is connected to the current spike (red conductor) at a distance of 20 meters
from the earth electrode
Earth Electrode Resistance Measurement Method (Figure 86)
This test must be repeated at least three times to ensure that the reading is not affected by interacting
earthing regions
i Record the first reading (Z1) Example Z1 = 10 Ω
ii Move the voltage spike to a distance of 6 meters from the original position Record the second
reading (Z2 ) Example Z2 = 10 Ω
iii Move the voltage spike to a distance of 6 meters from the original position Record the third
reading (Z3) Example Z3 = 10 Ω
66 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Residual Current Device Testi Ensure that the residual current device (RCD) trips within the set time on the occurrence of current
leakage to earth
ii Test Equipment ndash RCD Tester RCCB Tester
iii Test Method 1
1 1048766 Use the Trip Test Button
2 1048766 Press the trip button found on the RCD to determine if it trips or otherwise This test would
not be able to determine the sensitivity of the RCD nor the time taken for it to trip
iv Test Method 2
i 1048766 Use a RCD Tester
ii This equipment is equipped with a 13A plug which can be connected to a 13A socket outlet
Select the RCD sensitivity to be the same as the sensitivity of the RCD to be tested to
determine if the RCD can trip The time to trip shall not exceed 40 mS
iii 1048766 Test method ndash
a) Position the selection switch in accordance with the sensitivity of the RCD used
Example 100 mA 01 A
b) Position the operations switch to lsquoNo Triprsquo (frac12 Rated mA = 50) connect the 3 pin plug to
the 13A socket outlet
67 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
c) Switch on the 13A socket outlet ndash ensure that the P-N and P-E lights light up
This shows that the polarity is correct (Note if both the lights as above do not light up the test cannot
be continued)
d) Press the test button ndash the reading shows less than 200 mS and simultaneously the lsquotestrsquo light lights
up and the P-N and P-E lights do not light up At that instant the RCD will not trip
e) Move the selection switch to 180o (+ve wave) ndash repeat steps (d) and (e) Move the operations
switch to lsquoTriprsquo (Rated mA = 100)
g) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200mS
h) Move the selection switch to 0o (-ve wave)
i) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
j) The above test is repeated until a near correct reading is obtained
k) Record the test results
l) Change the operations switch to lsquoFast Triprsquo and press the test button ndash RCD will trip within a
time not exceeding 40 millisecond
m) Repeat a number of times at 0o or 180o
On completion of a wiring installation a number of tests on the installation have to be conducted to
ascertain that the wiring circuits and connected appliances are safe for use Prior to carrying out the
tests an inspection has to be done the following tests shall be conducted
i Continuity Test
ii Insulation Resistance Test
iii Polarity Test
iv Earth Electrode Resistance test and
v Residual Current Device Test
821 Continuity Test
There are 3 main types of continuity tests for the final circuits-
i Protection Conductor Continuity Test
ii Final Ring Circuit Conductor Continuity Test
68 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
iii Live and Neutral Conductor Continuity Test
a) Protection Conductor Continuity Test
bull To ascertain that all protection conductors are connected in the correct and effective manner
bull Test equipment ndash Multimeter (Ohm range) or Ohm meter
bull Test Method
1 1048766 Ensure that the main switch RCD and MCB are open circuited (switched off) and all loads are
disconnected
2 1048766 Connected the test leads as in the Figure 81
3 1048766 The meter reading shall be less than 1 Ω
Final Ring Circuit Conductor Continuity Test
bull To ensure that all conductors around the ring circuit have continuity
bull Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
bull Test Method
1 1048766 Disconnect both the supply source live conductors from the MCB the neutral conductor
from the neutral terminals and the earth conductor from the earth terminal in the distribution
fuse box
2 1048766 Connect the test leads as in the Figure 82 (EE)
3 1048766 Repeat the procedure for (L-L) and (N-N)
4 1048766 The meter reading value shall be less than 1 ohm Figure 82 - Final Ring Circuit Conductor
Continuity Test Ohm Meter
Disconnect both the supply source cables from mcbfuse
Take readings at earth conductors of both sources and note resistance readings
Live and Neutral Conductor Continuity Test
1 To ensure that each conductor in the circuit has continuity
2 Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
3 Test Method
1 1048766 Switch off the Main switch RCD and MCB
2 1048766 Disconnect all loads
3 1048766 Switch on all switches in the circuit
4 1048766 Disconnect the fusesfinal circuit breakers and close the circuit
5 1048766 Carry out the test as shown in Figure 83
6 1048766 The meter reading value shall be less than 1 ohm Figure 83 - Live and Neutral
Conductor Continuity Test Ohm Meter
Insulation Resistance Test
69 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
i Ensure that there is no leakage current between phase conductors phase and neutral conductors and
phase conductor and earth
ii Test the strength of the cable insulation
iii Test Equipment ndash Insulation Resistance Tester Operating voltage is 250VDC or 500VDC
iv Test Method
1 1048766 Switch off main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in the Table below
5 1048766 Meter reading value shall be less than 1 Megaohm
Polarity Test
i Ensure that each fuse or single pole control and protection device is connected only in the phase
conductor
ii Intermediate contact of Edison screw lamp holder is connected to the phase conductor
iii Ensure that phase neutral and earth conductors at socket outlets are connected at the correct
terminals
iv Test Equipment ndash Multimeter (Ohm range) or Ohm meter
v Test Method
1 1048766 Switch off Main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in Figure 85
5 1048766 Test switches and single phase control devices at the phase conductors
6 1048766 Test socket outlet connection sources
7 1048766 Test Edison screw lamp holder connections
8 1048766 Meter reading value shall be less than 1 Ω
Earth Electrode Resistance Test
i To test the earth electrode resistance
70 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
ii To ascertain the suitability of the location of the electrode
iii To ensure that the electrode is not buried within the resistance area of another electrode
iv Test equipment ndash Earth Resistance Tester
v Test method -
1 1048766 Terminal rsquoErsquo is connected to the electrode to be tested (green conductor)
2 1048766 Terminal lsquoPrsquo is connected to the potential spike (yellow conductor) at a distance of 10
meters from the earth electrode
3 1048766 Terminal lsquoCrsquo is connected to the current spike (red conductor) at a distance of 20 meters
from the earth electrode E P C Electrode 10 meter 10 meter
Figure 86 ndash Earth Electrode Resistance Measurement Test Equipment
Earth Electrode Resistance Measurement Method (Figure 86)
This test must be repeated at least three times to ensure that the reading is not affected by interacting
earthing regions
i Record the first reading (Z1) Example Z1 = 10 Ω
ii Move the voltage spike to a distance of 6 meters from the original position Record the second
reading (Z2) Example Z2 = 10 Ω
iii Move the voltage spike to a distance of 6 meters from the original position Record the third
reading (Z3)
Example Z3 = 10 Ω
Residual Current Device Test
71 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
i Ensure that the residual current device (RCD) trips within the set time on the occurrence of current
leakage to earth
ii Test Equipment ndash RCD Tester RCCB Tester
iii Test Method 1
1 1048766 Use the Trip Test Button
2 1048766 Press the trip button found on the RCD to determine if it trips or otherwise This test would
not be able to determine the sensitivity of the RCD nor the time taken for it to trip
iv Test Method 2
1048766 Use a RCD Tester
This equipment is equipped with a 13A plug which can be connected to a 13A socket outlet Select the
RCD sensitivity to be the same as the sensitivity of the RCD to be tested to determine if the RCD can
trip The time to trip shall not exceed 40 mS
1048766 Test method ndash
a) Position the selection switch in accordance with the sensitivity of the RCD used
Example 100 mA 01 A
b) Position the operations switch to lsquoNo Triprsquo (frac12 Rated mA = 50) connect the 3 pin plug to
the 13A socket outlet
c) Switch on the 13A socket outlet ndash ensure that the P-N and P-E lights light up This shows that
the polarity is correct (Note if both the lights as above do not light up the test cannot be
continued)
d) Press the test button ndash the reading shows less than 200 millisecond and simultaneously the
lsquotestrsquo light lights up and the P-N and P-E lights do not light up At that instant the RCD will
not trip
e) Move the selection switch to 180o (+ve wave) ndash repeat steps (d) and (e) = 100)
f) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
g) Move the selection switch to 0o (-ve wave)
h) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
i) The above test is repeated until a near correct reading is obtained
j) Record the test results
k) Change the operations switch to lsquoFast Triprsquo and press the test button ndash RCD will trip within a
time not exceeding 40 mS
l) Repeat a number of times at 0o or 180o
72 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 9 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (DC)
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
73 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Start stop button 240Vac 5A 2
9 Filament lamp (Bulb ) 240Vac 40W 3
10 Overload Relay 415V 20A 3
11 Three phase induction motor 5 hp 3
12 Single phase step down transformer 2500VA 1
13 Single core PVC insulated Cable 1mm 2 As required
14 Single core PVC insulated Cable 25mm 2 As required
15 DIN rail 35 mm As required
16 PVC type Cable tray 50 mm x 50 mm As required
17 Cable ties 4 ldquo As required
18 Flexible wires 05 mm As required
19 PVC Connectors 5 A amp 20 A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the schematic
diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a optional exercise
i Simple DOL starter
ii Forward reverse DOL starter
iii Forward Reverse Dahlander motor
iv Three motors operated in sequence by DOL starter operated by manual push
button or time delay relay
74 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
a One loop per-cycle
b Continuous operation in a loop
c optional circuit design to represent the same task
v Only one out of three motors to be operated at a time (quiz)
4 Test the functionality of completed project
LESSON 10 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (AC)
75 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 1
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Lamp point 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
76 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
11 Overload Relay 415V 20A 3
12 Three phase induction
motor
5 hp 3
13 Single core PVC insulated
Cable
1mm 2 As required
14 Single core PVC insulated
Cable
25mm 2 As required
15 DIN rail 35 mm As required
16 PVC type Cable tray 50 mm x 50 mm As required
17 Cable ties 4 ldquo As required
18 Flexible wires 05 mm As required
19 PVC Connectors 5 A amp 20 A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the
schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram optional exercise
4 Simple DOL starter
5 Forward reverse DOL starter
6 Test the functionality of completed project
77 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 1
78 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
cm
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Indicating light 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
11 Overload Relay 415V 20A 3
12 Three phase induction motor 5 hp 3
13 Single phase step down
transformer
2500VA 1
14 Single core PVC insulated
Cable
1mm 2 As required
15 Single core PVC insulated
Cable
25mm 2 As required
16 DIN rail 35 mm As required
17 PVC type Cable tray 50 mm x 50 mm As required
18 Cable ties 4 ldquo As required
19 Flexible wires 05 mm As required
20 PVC Connectors 5 A amp 20 A 240 V As required
21 Single pole MCB 6A 240 V 1
22 Single pole MCB 2A 240 V 1
23 Triple pole MCB 20A 415 V 1
24 Mounting board 30 cm x 40 cm x 3
cm
1
25 Relay cw 11 pin socket 10 A 240 Vac 2
26 Time delay relay 10 A 240 Vac 3
27 Triple pole Contactor 20A 240Vac 3
28 Batten type Lamp holder 240Vac 10 A 3
29 Start stop button 240Vac 10A 2
30 Indicating light (Bulb ) 240Vac 25W 3
31 Overload Relay 415V 20A 1
32 Three phase dahlander type
induction motor
5 hp 1
33 Single phase step down
transformer
24024Vac
2500VA
1
79 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
34 Single core PVC insulated
Cable
1mm 2 As required
35 Single core PVC insulated
Cable
25mm 2 As required
36 DIN rail 35 mm As required
37 PVC type Cable tray 50 mm x 50 mm As required
38 Cable ties 4 ldquo As required
39 Flexible wires 075 mm As required
40 PVC Connectors 5 A amp 20 A 240 V As required
41 Terminal block 20A 240Vac As required
Procedures
5 Identify each component according to specification and quantity required from the schematic
diagram attached
6 Test the functionality of each component by using multi-meter or power supply whichever
applicable
7 Wire component according to circuit diagram
8 Three motors operated in sequence by DOL starter operated by manual push button or time
delay relay
a One loop per-cycle
b Continuous operation in a loop
c optional circuit design to represent the same task
d Only one out of three motors to be operated at a time (quiz)
9 Test the functionality of completed project
80 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
BASIC DESIGN INDUSTRIAL MOTOR CONTROL (SEQUENCE CONTROL)
THREE PHASE INDUCTION MOTOR OPERATED IN SEQUENCE BY DIRECT ON LINE
STARTER
LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
81 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
82 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Lcd lamp indicator 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
11 Overload Relay 415V 20A 3
12 Three phase induction motor 5 hp 3
13 Single phase step down transformer 2500VA 1
14 Single core PVC insulated Cable 1mm 2 As required
15 Single core PVC insulated Cable 25mm 2 As required
16 DIN rail 35 mm As required
17 PVC type Cable tray 50 mm x 50 mm As required
18 Cable ties 4 ldquo As required
19 Flexible wires 1 mm Oslash As required
20 PVC Terminal block 10A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the schematic
diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a optional exercise
i Forward Reverse dahlander motor
4 Test the functionality of completed project
83 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
THREE PHASE DAHLANDER TYPE INDUCTION MOTOR OPERATED FORWARD AND
REVERSE OPERATION BY DIRECT ON LINE STARTER
84 ndash 99EASYTECH ENTERPRISE
LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
Introduction
If a motors windings are connected in the star configuration any two phases will be in series across
the supply and hence the line current will be smaller(by 577) than if the windings were connected in
the delta arrangement
Hence larger-type motors with heavy starting currents are first connected in star and then when the
starting currents fall in delta This of course means that all six of the ends of the windings must be
brought to terminations outside the casing (Fig 833)
EZTECH
EZTECH ELECTRICAL INSTALLATION GUIDE
The automatic version of this starter incorporates a timing relay which automatically changes the
connections from star to delta Figs 834 and 835 show the wiring and schematic diagrams for a star
delta starter
Objectives
1 Identify component and the specification
2 Design forward reverse star delta starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
2 ndash 99EASYTECH ENTERPRISE
REV -C
LEGENDMCCB Moulded Case Circuit BreakerTOR Thermal Over Load RelayFOW-C Mains Forward ContactorREV-C Mains Reverse ContactorDC Delta ContactorSC Star ContactorS-SW Mains Selector Switch
SC
V2
W2
U2
DC
V1
W1
U1
TOR
TOR
FOW-C
30A MCCB
TOR
MAIN CIRCUIT FORWARD REVERSE STAR DELTA
RYBN S
-SW
3 PHASEINDUCTION MOTOR
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Relay 10 A 240V 3
5 Triple pole Contactor
6 cw NO NC auxiliary contact
240Vac 20 A 4
7 Overload Relay 415 V 1
8 LED indicator 240vac 5 A 4
9 Start stop button 240Vac 5A 2
10 DIN rail 35 mm As required
11 Flexible wires 1 mm As required
12 Single core PVC insulated
wire
25 mm As required
13 Terminal block 20 A As required
14 Squirrel cage motor 5kW 1
15 5 pin plug and socket 415V 20A 1
16 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
3 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
a Manual star delta
b Manual Forward reverse star delta starter
c Automatic star delta starter
d Automatic Forward reverse star delta starter
4 Test the functionality of completed project
4 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
Objectives
1 Identify component and the specification
2 Design auto transformer starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
5 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Autotransformer starter is used to start a 3 phase induction motor that has a rating between 10 to 15 hp
6 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Autotransformer set 10Kw 415 V 50 Hz 1
5 Triple pole Contactor 240Vac 4
6 Batten type Lamp holder 240 Vac 105 A 4
7 Start stop button 240Vac 10A 4
8 Filament lamp (Bulb ) 240Vac 40W 4
9 DIN rail 35 mm As required
10 Flexible wires 1 mm As required
7 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
11 Single core PVC insulated
wire
25 mm As required
12 Terminal block 20 A As required
13 Squirrel cage motor 10kW 1
14 5 pin plug and socket 415V 20A 1
15 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a open transient autotransformer starter
b close transient autotransformer starter
c Forward reverse autotransformer starter
4 Test the functionality of completed project
8 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
Objectives
1 Identify component and the specification
2 Design rotor resistance starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
9 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Rotor Resistor set 10kW 1
5 Triple pole Contactor 240Vac 20A 4
6 Indicating light 240vac 5 A 4
7 Start stop push button 240Vac 5A 4
8 DIN rail 35 mm As required
9 Flexible wires 1 mm 2 As required
10 Single core PVC insulated wire 25 mm 2 As required
11 Terminal block 20 A As required
12 Slip Ring motor 10kW 1
13 5 pin round 3 phase socket 415V 20A 1
14 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
10 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
4 Test the functionality of completed project
a Dead circuit test b Life circuit test
5 Measure starting and running Amps
LESSON 16
TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
An installation in general will suffer damage
Damage usually occurs on the electric motor control as follows
1 Damage to the main circuit
2 Damage to the control circuit
The cause of the damage
i Overcurrent overload short circuit
ii Leakage current to ground
iii Equipment malfunction
iv The main control circuit
a Trip of main circuit protection devices fire
b Defect of motor terminal such as short circuit fire loose
v The control circuit is not functioning -
a contactor relay relay time overload relay does not work damaged burned
b Loose cable connection disconnected
Detecting and Repairing Damage
Examples of damage are as follows
i Motor does not work
ii Motor function and overload relay trips
iii Motor function but only partially functional control circuit
Methods of detecting damage
Among the known methods necessary to detect damage are as follows
1 Turn off the electricity at the main switch (main switch) in order to avoid any danger during the
work carried out to detect damage
2 Check all the protective gear that controls the motor control main circuit
11 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
3 Make sure the damage function control circuit
4 Check the control circuit according to the schematic circuit diagram of the motor control
5 Check the operation of the control circuit
Note
Use wiring that has been installed on the SYSTEM OF MOTOR CONTROL BOARD by Forward
Reverse control circuit for Star Delta to test and look for damage
SELF-ASSESSMENT QUESTIONS
1 (a) Explain what is meant by the term lsquoback emfrsquo in a motor
(b) Outline the basic differences between series shunt and compound wound dc motors
2 (a) With the aid of diagrams explain how the speed of series shunt and compound-wound motors
may be controlled
(b) A 440V dc shunt-wound motor has a field resistance of 200R and an armature resistance of 06 R
When its speed is 20 rev d second the current drawn from the supply is 122A Calculate its back
emf at this speed If the speed were decreased to 19 revssecond the field flux remaining unchanged
calculate the new back emf and the new armature current
3 A load of 64 kW at 240 V is supplied from the terminals of a shunt-wound dc generator The field
resistance is 180 A Calculate the armature current
4 (a) Explain with the aid of a diagram how a rotating magnetic field may be
(b) What is meant by lsquosynchronous speedrsquo
Calculate the synchronous obtained speed of a 12 pole motor if the supply frequency is 50Hz
5 (a) Explain the action of a synchronous motor
(b) What methods are available to start a synchronous motor Explain with diagrams
6 (a) Explain the action of a cage induction motor
(b) What is meant by the term lsquosliprsquo
Calculate the percentage slip of a six pole induction motor running at 162 revssecond from a 50 Hz
supply
7 Describe with sketches three different ways of starting a single-phase induction motor
12 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
8 Explain with the aid of a sketch the action of a three-phase DOL starter
What are dashpots used for How are remote start and stop buttons connected
9 A I0 kW 240V 50Hz single-phase cage rotor induction motor is 85efficient and has a PF of 068
lagging Calculate the motor current and the value of capacitor required to raise the PF to 093
lagging
10 Calculate the torque developed by an 18 kW four-pole induction motor run at 35 slip from a
50Hz supply
APPENDIX 1
13 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 11
14 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 111
Attachment Reference
httpswwwtlc-directcoukBook621htm
httpwwwstgovmyindexphpms
15 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Closed Transition State The Main [KM3] contactor is closed and the Delta [KM2] and Star
[KM1] contactors are open Current flows through the motor windings and the transition resistors
via KM4
Delta State The Main and the Delta contactors are closed The transition resistors are shorted out
The Star contactor is open The motor is connected to full line voltage and full power and torque
are available
Effect of Transient in Starter (Open Transient starter)
It is Important the pause between star contactor switch off and Delta contactor switch is on correct
This is because Star contactor must be reliably disconnected before Delta contactor is activated It
is also important that the switch over pause is not too long
For 415v Star Connection voltage is effectively reduced to 58 or 240v The equivalent of 33
that is obtained with Direct Online (DOL) starting
If Star connection has sufficient torque to run up to 75 or 80 of full load speed then the motor
can be connected in Delta mode
When connected to Delta configuration the phase voltage increases by a ratio of V3 or 173 The
phase currents increase by the same ratio The line current increases three times its value in star
connection
During transition period of switchover the motor must be free running with little deceleration
While this is happening ldquoCoastingrdquo it may generate a voltage of its own and on connection to the
supply this voltage can randomly add to or subtract from the applied line voltage This is known as
transient current Only lasting a few milliseconds it causes voltage surges and spikes Known as
a changeover transient
Size of each part of Star-Delta starter
(1) Size of Over Load Relay
For a star-delta starter there is a possibility to place the overload protection in two positions in the
line or in the windings
Overload Relay in Line
In the line is the same as just putting the overload before the motor as with a DOL starter
The rating of Overload (In Line) = FLC of Motor
Disadvantage If the overload is set to FLC then it is not protecting the motor while it is in delta
(setting is x1732 too high)
Overload Relay in Winding
25 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
In the windings means that the overload is placed after the point where the wiring to the contactors
are split into main and delta The overload then always measures the current inside the windings
The setting of Overload Relay (In Winding) =058 X FLC (line current)
Disadvantage We must use separate short circuit and overload protections
(2) Size of Main and Delta Contractor
1 There are two contactors that are close during run often referred to as the main contractor and
the delta contactor These are AC3 rated at 58 of the current rating of the motor
Size of Main Contactor= IFL x 058
(3) Size of Star Contractor
The third contactor is the star contactor and that only carries star current while the motor is
connected in star The current in star is 1 radic3= (58) of the current in delta so this contactor can
be AC3 rated at one third (33) of the motor rating
Size of Star Contactor= IFL x 033
Motor Starting Characteristics of Star-Delta Starter
Available starting current 33 Full Load Current
Peak starting current 13 to 26 Full Load Current
Peak starting torque 33 Full Load Torque
Advantages of Star-Delta starter
The operation of the star-delta method is simple and rugged
It is relatively cheap compared to other reduced voltage methods
Good TorqueCurrent Performance
It draws 2 times starting current of the full load ampere of the motor connected
Disadvantages of Star-Delta starter
Low Starting Torque (Torque = (Square of Voltage) is also reduce)
Break In Supply ndash Possible Transients
Six Terminal Motor Required (Delta Connected)
It requires 2 set of cables from starter to motor
It provides only 33 starting torque and if the load connected to the subject motor requires higher
starting torque at the time of starting than very heavy transients and stresses are produced while
changing from star to delta connections and because of these transients and stresses many
electrical and mechanical break-down occurs
26 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
In this method of starting initially motor is connected in star and then after change over the motor
is connected in delta The delta of motor is formed in starter and not on motor terminals
High transmission and current peaks When starting up pumps and fans for example the load
torque is low at the beginning of the start and increases with the square of the speed When
reaching approx 80-85 of the motor rated speed the load torque is equal to the motor torque and
the acceleration ceases To reach the rated speed a switch over to delta position is necessary and
this will very often result in high transmission and current peaks In some cases the current peak
can reach a value that is even bigger than for a DOL start
Applications with a load torque higher than 50 of the motor rated torque will not be able to start
using the start-delta starter
Low Starting Torque The star-delta (wye-delta) starting method controls whether the lead
connections from the motor are configured in a star or delta electrical connection The initial
connection should be in the star pattern that results in a reduction of the line voltage by a factor of
1radic3 (577) to the motor and the current is reduced to 13 of the current at full voltage but the
starting torque is also reduced 13 to 15 of the DOL starting torque
The transition from star to delta transition usually occurs once nominal speed is reached but is
sometimes performed as low as 50 of nominal speed which make transient Sparks
Features of star-delta starting
1 For low- to high-power three-phase motors
2 Reduced starting current
3 Six connection cables
4 Reduced starting torque
5 Current peak on changeover from star to delta
6 Mechanical load on changeover from star to delta
Application of Star-Delta Starter
The star-delta method is usually only applied to low to medium voltage and light starting
Torque motors
The received starting current is about 30 of the starting current during direct on line start and the
starting torque is reduced to about 25 of the torque available at a DOL start This starting
method only works when the application is light loaded during the start If the motor is too heavily
27 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
loaded there will not be enough torque to accelerate the motor up to speed before switching over
to the delta position
LESSON 1 WIRING SYSTEM OF SINGLE PHASE DISTRIBUTION BOARD
Introduction
28 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
29 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
30 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
31 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 2 WIRING SYSTEM OF SINGLE PHASE LIGHTING CIRCUIT Introduction
Objectives
1 Identify component and the specification
2 Wire component according to the schematic diagram
3 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Wiring bay Perforated metal 180 cm x 180 cm 1
2 Cut out fuse 63 A 240 V 1
3 Neutral link 1
4 Single pole one way switch cw
switch box
5A 240Vac 4
5 single pole two way switch cw
switch box
5A 240Vac 2
6 RCCB In = 40 A Tripping current
100mA240 Vac 50 Hz
1
7 Main switch 32 A 240V 1
8 kWatthour meter 40 A 240 Vac 1
9 Single pole MCB 6A 240 Vac 1
10 Self tapping Wood screw As required
11 DIN rail 35 mm width As required
32 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
12 PVC trunking 50 mm x 50 mm As required
13 Terminal blocks 5 A As required
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
1 One way switch to control one lamp
2 One way switch to control two lamps
3 Two of two way switch to control one lamp
4 Two of single pole two way switch and one of an intermediate switch to control one
lamp
5 One unit of ceiling fan and fan regulator to be controlled by one way switch
4 Test the functionality of completed project
LESSON 3ndash WIRING SYSTEM OF SINGLE PHASE POWER CIRCUIT Introduction
33 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
34 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify types of component and its specification
2 Wire component according to the schematic diagram given
3 Test the functionality of the circuit dead circuit test life circuit test
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board Perforated Metal 1
2 kWh meter 240 V 40 A 1
3 Socket outlet 13A 240Vac 4
4 RCCB 40A Trip Amps
30mA240 Vac
1
5 3 pin socket 240Vac 13A 4
6 Single pole MCB 20A 240 V 2
7 DOL starter 1 kW 240Vac 2
8 1 phase induction motor 2Hp 240 Vac 1
9 Cooker control unit 4kW 240Vac 1
10 Water heater point 4kW 240 Vac 1
11 DIN rail 35 mm As required
12 PVC casing 20mm As required
13 Flexible wires 05 mm As required
14 Terminal block 10 A As required
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Wire two unit of 13 A socket outlet in radial circuit
3 Wire four units of 13 A socket outlet in ring circuit
4 Wire one unit DOL starter for air-conditioner point
5 Wire one unit of cooker control unit point
6 Wire one unit of water heater point
7 Test the functionality of each component by using mmeter or power supply whichever
applicable
8 Wire component according to circuit diagram
9 Test the functionality of completed project dead circuit test life circuit test
Note
35 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Ensure that the correct rating of protection device and size of wire used
LESSON 4ndash CONDUIT BENDING AND TRUNKING FABRICATION TECHNIQUE
Common fitting used in an industrial wiring
Cutting and threading the condute
36 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
37 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
38 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify conduit fitting and the specification
2 Measure and Cut steel conduit according to specified dimension
3 Bend and fabricate conduit at 45 90 according to layout diagram
4 Wire component according to the schematic diagram
5 Test the functionality of the circuit
39 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Conduit Bender Oslash 19 mm ( frac34 ldquo) 1
2 Measuring Tape 3 metre 1
3 Hacksaw frame and blade 30cm 1
4 Conduit cutter 1
5 Pipe Vise 1
6 Pipe Wrench 1
7 Ratchet Dies 20 mm 1
8 Metal trunking 50 mm x 50 mm 1
9 GI conduit 20mm 1
10 End box 20 mm 1
11 Flexible wires 05 mm As required
12 Connectors 5 A As required
13 Single core PVC ins Cable 25 mm 2 As required
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Wire two unit of 13 A socket outlet in radial circuit
3 Wire four unit of 13 A socket outlet in ring circuit
4 Wire one unit DOL starter for air-conditioner point
5 Wire one unit of cooker control unit point
6 Wire one unit of water heater point
7 Test the functionality of each component by using multimeter or power supply whichever
applicable
8 Wire component according to circuit diagram
9 Test the functionality of completed project
Note
Ensure that the rating of protection device and size of wire
K prior to 31 March
2004 (BS 7671)
(formerly)
bare conductor
sleeved at terminations (formerly)
40 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 5 ndashWIRING SYSTEM OF 1 Oslash LIGHTING AND POWER CIRCUIT
POWER CIRCUITSa Radial circuits
Radial circuits are arranged in the same way as item 1 above in lighting layouts in that each socket
outlet is supplied via the previous one
Points to note
1 The number of socket outlets complying with BS 1363 is unlimited for a floor area of up to 50m 2 if
the circuit protection is a 30 A or 32 A cartridge fuse or circuit breaker the cable being 4 mm PVC
copper or 25 mm2 mineral insulated (mi)
2 The number of socket outlets is unlimited for a floor area up to 20 m 2 with any type of circuit
protection of 20 A using 25 mm2 PVC copper cable or 15 mm2 mi
3 The total number of fused spurs is unlimited
b ring final circuits
These circuits are the same as radial circuits except that the final socket outlet is wired back to the
supply position In effect any outlet is supplied from two directions (Fig 152)
Points to note
1 Every twin-socket outlet counts as two single-socket outlets
2 The number of non-fused spurs must not exceed the total number of points on the ring Fig 158
shows seven points on the ring and five spurs
3 The fuse rating of a fused spur box must not exceed 13 A and the current rating of all points supplied
by the fused spur must not exceed 13 A
4 Non-fused spurs must supply no more than one single or one double socket on the ring Fig 158
shows seven points on the ring and five spurs rating of all points supplied by the fused spur must not
exceed 13 A or one stationary appliance
CapacityMain conductor size
copper (mm2)
Earth conductor
size (mm2)
Circuit breaker
capacity (A)
Up to 600 W 15 15 6
600ndash1200 W 1525 15 10
1200ndash1800 W 254 25 16
41 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Ring circuit
(floor area 100 m2)25 15 3032
A2 radial circuit
(floor area 75 m2)40 25 3032
A3 radial circuit
(floor area 50 m2)25 15 20
Air conditioner (15 tonne) 60 60 3032
Cooker 60 60 3032
Water heater 40 40 20
Objectives
1 Identify component and the specification
2 Wire component according to the schematic diagram
3 Test the functionality of the circuit
42 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board Perforated 1
2 Cut out fuse and neutral link 60A 240V 1each
3 kWh meter 240V 40A 1
4 Switched Socket outlet 13A 240Vac 4
5 Single pole two way switch cw switch
box
5A 240Vac 2
6 RCCB ELCB 63 A Tripping current 100mA
415 Vac
1
7 3 pin plug 240Vac 13A 4
8 Single pole MCB 20 A 2
9 Single pole MCB 6A 1
10 Single pole MCB 20A 2
11 DOL starter 240Vac 2
12 1 phase induction motor 2hp 240 Vac 1
13 Self tapping Wood screw As required
14 DIN rail Stainless steel allum35 mm As required
15 PVC pipe 20mm dia As required
16 End box 20 mm dia 4
17 Flexible wires 05 mm 2 As required
18 Connectors 5 A As required
Procedures
43 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
4 Test the functionality of completed project
LESSON 6 ndash WIRING SYSTEM OF 3 Oslash DISTRIBUTION BOARD
Introduction
44 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
45 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
46 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
47 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
48 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify each component and the specification
2 Wire component according to the schematic diagram given
3 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting Board 450 x 600 mm Perforated metal 1
2 5 pin round socket and plug 415V ac 32A 1
3 Cut out fuse 60 A 3
4 Neutral link 1
5 kWatt hour meter 415V 60A 1
6 ELCB RCCB 3P+N In=63A415 Vac I trip= 300mA 1
7 ELCB RCCB 3P+N In=63A415 Vac I trip= 30mA 1
8 Single pole MCB 6A 240 V 3
9 Single pole MCB 20A 240 V 3
10 DOL starter 20 A 240Vac 2
11 Socket outlet 15 A 240 Vac 1
12 Switched Socket outlet 13 A 240 Vac 3
13 Led indicating light 5A 240 Vac 3
14 Single pole 4 gang 1 way switch 5A 240 Vac 2
15 Single pole 2 way switch 5A 240 Vac 2
16 1 phase induction motor 1 kW 240Vac 1
17 Metal trunking 30 mm x30 mm As required
18 Self tapping Wood screw 4 mm x 20 mm As required
19 DIN rail 25 mm x 1mm
20 GI steel rigid conduit 20mm As required
21 Flexible conduit 20mm As required
22 End box 20 mm 4
23 Flexible wires 05 mm 2 As required
24 Single core PVC insulated wire 15 mm 2 As required
25 Single core PVC insulated wires 25 mm 2 As required
26 Terminal block 10 A As required
Procedures
49 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify each components and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
4 Test the functionality of completed project
1 dead circuit test
2 life circuit
Note Proper earthing should be made
50 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 7 ndash WIRING SYSTEM OF THREE PHASE LIGHTING AND POWER CIRCUIT
51 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
52 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify component and the specification
2 Wire component according to the schematic diagram
3 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting bay Board Perforated metal 180 cm x 180 cm 1
2 k Watt hour meter 415V 60A 1
3 MCCB 415V 60A
4 ELCB RCCB In=60A415 Vac I trip=30mA 1
5 5 pin round Socket and
plug
415Vac 32A 4
6 Single pole MCB 6A 1
7 Triple pole MCB 20A 2
8 Triple pole Main switch 60A 1
9 DOL starter 240Vac 2
10 3 phase induction motor 2hp 415 Vac 1
11 1 phase induction motor 1
12 Metal trunking 30 mm x30 mm As required
13 Self tapping Wood screw 4 mm x 20 mm As required
14 DIN rail 25 mm x 1mm
15 GI steel rigid conduit 20mm As required
16 Flexible conduit 20mm As required
17 End box 20 mm 4
18 Flexible wires 05 mm As required
19 Connectors 10 A As required
Procedures
1 Identify each components and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
4 Test the functionality of completed project
1 dead circuit 2 life circuit test
5 Record the current drawn by the load as connected in star and delta
Note Proper earthing should be made
53 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 8 INSPECTION AND TESTING OF ELECTRICAL INSTALLATION
On completion of a wiring installation a number of tests on the installation have to be conducted to
ascertain that the wiring circuits and connected appliances are safe for use Prior to carrying out the
tests an inspection has to be done The results of the inspectionsupervision and test have to be
presented in Form G (as in Appendix IV) and Form H (as in Appendix V)
To have the test certification as in Form H the following tests shall be conducted
i Continuity Test
ii Insulation Resistance Test
iii Polarity Test
iv Earth Electrode Resistance test and
v Residual Current Device Test
1 Continuity Test
There are 3 main types of continuity tests for the final circuits-
i Protection Conductor Continuity Test
ii Final Ring Circuit Conductor Continuity Test
iii Live and Neutral Conductor Continuity Test
a) Protection Conductor Continuity Test
bull To ascertain that all protection conductors are connected in the correct and effective manner
bull Test equipment ndash Multimeter (Ohm range) or Ohm meter
54 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
bull Test Method
1 1048766 Ensure that the main switch RCD and MCB are open circuited (switched off) and all loads
are disconnected
2 1048766 Connected the test leads as in the Figure 81 The meter reading shall be less than 1 Ω
55 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Final Ring Circuit Conductor Continuity Test
bull To ensure that all conductors around the ring circuit have continuity
bull Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
bull Test Method
1 1048766 Disconnect both the supply source live conductors from the MCB the neutral conductor
from the neutral terminals and the earth conductor from the earth terminal in the distribution
fuse box
2 1048766 Connect the test leads as in the Figure 82 (EE)
3 1048766 Repeat the procedure for (L-L) and (N-N)
4 1048766 The meter reading value shall be less than 1 ohm
56 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Live and Neutral Conductor Continuity Test
a To ensure that each conductor in the circuit has continuity
b Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
2 Test Method
1 1048766 Switch off the Main switch RCD and MCB
2 1048766 Disconnect all loads
3 1048766 Switch on all switches in the circuit
4 1048766 Disconnect the fusesfinal circuit breakers and close the circuit
5 1048766 Carry out the test as shown in Figure 83
6 1048766 The meter reading value shall be less than 1Ω
57 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
58 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
CONTINUITY TEST
Insulation Resistance Test
i Ensure that there is no leakage current between phase conductors phase and neutral conductors and
phase conductor and earth
ii Test the strength of the cable insulation
iii Test Equipment ndash Insulation Resistance Tester operating voltage is 250VDC or 500VDC
iv Test Method
1 1048766 Switch off main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
59 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
4 1048766 Carry out test as in the Table below
5 1048766 Meter reading value shall be less than 1 Megaohm
60 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
61 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Insulation resitance test
62 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
INSULATION RESISTANCE TEST BETWEEN CONDUCTORS AND OPPOSITE POLARITY
Polarity Testi Ensure that each fuse or single pole control and protection device is connected only in the phase
conductor
ii Intermediate contact of Edison screw lamp holder is connected to the phase conductor
iii Ensure that phase neutral and earth conductors at socket outlets are connected at the correct
terminals
iv Test Equipment ndash Multimeter (Ohm range) or Ohm meter
v Test Method
1 1048766 Switch off Main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in Figure 85
63 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
5 1048766 Test switches and single phase control devices at the phase conductors
6 1048766 Test socket outlet connection sources
7 1048766 Test Edison screw lamp holder connections
8 1048766 Meter reading value shall be less than 1 Ω
64 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Polarity test
65 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Earth Electrode Resistance Testi To test the earth electrode resistance
ii To ascertain the suitability of the location of the electrode
iii To ensure that the electrode is not buried within the resistance area of another electrode
iv Test equipment ndash Earth Resistance Tester
v Test method -
1 1048766 Terminal rsquoErsquo is connected to the electrode to be tested (green conductor)
2 1048766 Terminal lsquoPrsquo is connected to the potential spike (yellow conductor) at a distance of 10
meters from the earth electrode
3 1048766 Terminal lsquoCrsquo is connected to the current spike (red conductor) at a distance of 20 meters
from the earth electrode
Earth Electrode Resistance Measurement Method (Figure 86)
This test must be repeated at least three times to ensure that the reading is not affected by interacting
earthing regions
i Record the first reading (Z1) Example Z1 = 10 Ω
ii Move the voltage spike to a distance of 6 meters from the original position Record the second
reading (Z2 ) Example Z2 = 10 Ω
iii Move the voltage spike to a distance of 6 meters from the original position Record the third
reading (Z3) Example Z3 = 10 Ω
66 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Residual Current Device Testi Ensure that the residual current device (RCD) trips within the set time on the occurrence of current
leakage to earth
ii Test Equipment ndash RCD Tester RCCB Tester
iii Test Method 1
1 1048766 Use the Trip Test Button
2 1048766 Press the trip button found on the RCD to determine if it trips or otherwise This test would
not be able to determine the sensitivity of the RCD nor the time taken for it to trip
iv Test Method 2
i 1048766 Use a RCD Tester
ii This equipment is equipped with a 13A plug which can be connected to a 13A socket outlet
Select the RCD sensitivity to be the same as the sensitivity of the RCD to be tested to
determine if the RCD can trip The time to trip shall not exceed 40 mS
iii 1048766 Test method ndash
a) Position the selection switch in accordance with the sensitivity of the RCD used
Example 100 mA 01 A
b) Position the operations switch to lsquoNo Triprsquo (frac12 Rated mA = 50) connect the 3 pin plug to
the 13A socket outlet
67 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
c) Switch on the 13A socket outlet ndash ensure that the P-N and P-E lights light up
This shows that the polarity is correct (Note if both the lights as above do not light up the test cannot
be continued)
d) Press the test button ndash the reading shows less than 200 mS and simultaneously the lsquotestrsquo light lights
up and the P-N and P-E lights do not light up At that instant the RCD will not trip
e) Move the selection switch to 180o (+ve wave) ndash repeat steps (d) and (e) Move the operations
switch to lsquoTriprsquo (Rated mA = 100)
g) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200mS
h) Move the selection switch to 0o (-ve wave)
i) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
j) The above test is repeated until a near correct reading is obtained
k) Record the test results
l) Change the operations switch to lsquoFast Triprsquo and press the test button ndash RCD will trip within a
time not exceeding 40 millisecond
m) Repeat a number of times at 0o or 180o
On completion of a wiring installation a number of tests on the installation have to be conducted to
ascertain that the wiring circuits and connected appliances are safe for use Prior to carrying out the
tests an inspection has to be done the following tests shall be conducted
i Continuity Test
ii Insulation Resistance Test
iii Polarity Test
iv Earth Electrode Resistance test and
v Residual Current Device Test
821 Continuity Test
There are 3 main types of continuity tests for the final circuits-
i Protection Conductor Continuity Test
ii Final Ring Circuit Conductor Continuity Test
68 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
iii Live and Neutral Conductor Continuity Test
a) Protection Conductor Continuity Test
bull To ascertain that all protection conductors are connected in the correct and effective manner
bull Test equipment ndash Multimeter (Ohm range) or Ohm meter
bull Test Method
1 1048766 Ensure that the main switch RCD and MCB are open circuited (switched off) and all loads are
disconnected
2 1048766 Connected the test leads as in the Figure 81
3 1048766 The meter reading shall be less than 1 Ω
Final Ring Circuit Conductor Continuity Test
bull To ensure that all conductors around the ring circuit have continuity
bull Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
bull Test Method
1 1048766 Disconnect both the supply source live conductors from the MCB the neutral conductor
from the neutral terminals and the earth conductor from the earth terminal in the distribution
fuse box
2 1048766 Connect the test leads as in the Figure 82 (EE)
3 1048766 Repeat the procedure for (L-L) and (N-N)
4 1048766 The meter reading value shall be less than 1 ohm Figure 82 - Final Ring Circuit Conductor
Continuity Test Ohm Meter
Disconnect both the supply source cables from mcbfuse
Take readings at earth conductors of both sources and note resistance readings
Live and Neutral Conductor Continuity Test
1 To ensure that each conductor in the circuit has continuity
2 Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
3 Test Method
1 1048766 Switch off the Main switch RCD and MCB
2 1048766 Disconnect all loads
3 1048766 Switch on all switches in the circuit
4 1048766 Disconnect the fusesfinal circuit breakers and close the circuit
5 1048766 Carry out the test as shown in Figure 83
6 1048766 The meter reading value shall be less than 1 ohm Figure 83 - Live and Neutral
Conductor Continuity Test Ohm Meter
Insulation Resistance Test
69 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
i Ensure that there is no leakage current between phase conductors phase and neutral conductors and
phase conductor and earth
ii Test the strength of the cable insulation
iii Test Equipment ndash Insulation Resistance Tester Operating voltage is 250VDC or 500VDC
iv Test Method
1 1048766 Switch off main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in the Table below
5 1048766 Meter reading value shall be less than 1 Megaohm
Polarity Test
i Ensure that each fuse or single pole control and protection device is connected only in the phase
conductor
ii Intermediate contact of Edison screw lamp holder is connected to the phase conductor
iii Ensure that phase neutral and earth conductors at socket outlets are connected at the correct
terminals
iv Test Equipment ndash Multimeter (Ohm range) or Ohm meter
v Test Method
1 1048766 Switch off Main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in Figure 85
5 1048766 Test switches and single phase control devices at the phase conductors
6 1048766 Test socket outlet connection sources
7 1048766 Test Edison screw lamp holder connections
8 1048766 Meter reading value shall be less than 1 Ω
Earth Electrode Resistance Test
i To test the earth electrode resistance
70 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
ii To ascertain the suitability of the location of the electrode
iii To ensure that the electrode is not buried within the resistance area of another electrode
iv Test equipment ndash Earth Resistance Tester
v Test method -
1 1048766 Terminal rsquoErsquo is connected to the electrode to be tested (green conductor)
2 1048766 Terminal lsquoPrsquo is connected to the potential spike (yellow conductor) at a distance of 10
meters from the earth electrode
3 1048766 Terminal lsquoCrsquo is connected to the current spike (red conductor) at a distance of 20 meters
from the earth electrode E P C Electrode 10 meter 10 meter
Figure 86 ndash Earth Electrode Resistance Measurement Test Equipment
Earth Electrode Resistance Measurement Method (Figure 86)
This test must be repeated at least three times to ensure that the reading is not affected by interacting
earthing regions
i Record the first reading (Z1) Example Z1 = 10 Ω
ii Move the voltage spike to a distance of 6 meters from the original position Record the second
reading (Z2) Example Z2 = 10 Ω
iii Move the voltage spike to a distance of 6 meters from the original position Record the third
reading (Z3)
Example Z3 = 10 Ω
Residual Current Device Test
71 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
i Ensure that the residual current device (RCD) trips within the set time on the occurrence of current
leakage to earth
ii Test Equipment ndash RCD Tester RCCB Tester
iii Test Method 1
1 1048766 Use the Trip Test Button
2 1048766 Press the trip button found on the RCD to determine if it trips or otherwise This test would
not be able to determine the sensitivity of the RCD nor the time taken for it to trip
iv Test Method 2
1048766 Use a RCD Tester
This equipment is equipped with a 13A plug which can be connected to a 13A socket outlet Select the
RCD sensitivity to be the same as the sensitivity of the RCD to be tested to determine if the RCD can
trip The time to trip shall not exceed 40 mS
1048766 Test method ndash
a) Position the selection switch in accordance with the sensitivity of the RCD used
Example 100 mA 01 A
b) Position the operations switch to lsquoNo Triprsquo (frac12 Rated mA = 50) connect the 3 pin plug to
the 13A socket outlet
c) Switch on the 13A socket outlet ndash ensure that the P-N and P-E lights light up This shows that
the polarity is correct (Note if both the lights as above do not light up the test cannot be
continued)
d) Press the test button ndash the reading shows less than 200 millisecond and simultaneously the
lsquotestrsquo light lights up and the P-N and P-E lights do not light up At that instant the RCD will
not trip
e) Move the selection switch to 180o (+ve wave) ndash repeat steps (d) and (e) = 100)
f) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
g) Move the selection switch to 0o (-ve wave)
h) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
i) The above test is repeated until a near correct reading is obtained
j) Record the test results
k) Change the operations switch to lsquoFast Triprsquo and press the test button ndash RCD will trip within a
time not exceeding 40 mS
l) Repeat a number of times at 0o or 180o
72 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 9 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (DC)
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
73 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Start stop button 240Vac 5A 2
9 Filament lamp (Bulb ) 240Vac 40W 3
10 Overload Relay 415V 20A 3
11 Three phase induction motor 5 hp 3
12 Single phase step down transformer 2500VA 1
13 Single core PVC insulated Cable 1mm 2 As required
14 Single core PVC insulated Cable 25mm 2 As required
15 DIN rail 35 mm As required
16 PVC type Cable tray 50 mm x 50 mm As required
17 Cable ties 4 ldquo As required
18 Flexible wires 05 mm As required
19 PVC Connectors 5 A amp 20 A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the schematic
diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a optional exercise
i Simple DOL starter
ii Forward reverse DOL starter
iii Forward Reverse Dahlander motor
iv Three motors operated in sequence by DOL starter operated by manual push
button or time delay relay
74 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
a One loop per-cycle
b Continuous operation in a loop
c optional circuit design to represent the same task
v Only one out of three motors to be operated at a time (quiz)
4 Test the functionality of completed project
LESSON 10 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (AC)
75 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 1
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Lamp point 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
76 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
11 Overload Relay 415V 20A 3
12 Three phase induction
motor
5 hp 3
13 Single core PVC insulated
Cable
1mm 2 As required
14 Single core PVC insulated
Cable
25mm 2 As required
15 DIN rail 35 mm As required
16 PVC type Cable tray 50 mm x 50 mm As required
17 Cable ties 4 ldquo As required
18 Flexible wires 05 mm As required
19 PVC Connectors 5 A amp 20 A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the
schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram optional exercise
4 Simple DOL starter
5 Forward reverse DOL starter
6 Test the functionality of completed project
77 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 1
78 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
cm
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Indicating light 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
11 Overload Relay 415V 20A 3
12 Three phase induction motor 5 hp 3
13 Single phase step down
transformer
2500VA 1
14 Single core PVC insulated
Cable
1mm 2 As required
15 Single core PVC insulated
Cable
25mm 2 As required
16 DIN rail 35 mm As required
17 PVC type Cable tray 50 mm x 50 mm As required
18 Cable ties 4 ldquo As required
19 Flexible wires 05 mm As required
20 PVC Connectors 5 A amp 20 A 240 V As required
21 Single pole MCB 6A 240 V 1
22 Single pole MCB 2A 240 V 1
23 Triple pole MCB 20A 415 V 1
24 Mounting board 30 cm x 40 cm x 3
cm
1
25 Relay cw 11 pin socket 10 A 240 Vac 2
26 Time delay relay 10 A 240 Vac 3
27 Triple pole Contactor 20A 240Vac 3
28 Batten type Lamp holder 240Vac 10 A 3
29 Start stop button 240Vac 10A 2
30 Indicating light (Bulb ) 240Vac 25W 3
31 Overload Relay 415V 20A 1
32 Three phase dahlander type
induction motor
5 hp 1
33 Single phase step down
transformer
24024Vac
2500VA
1
79 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
34 Single core PVC insulated
Cable
1mm 2 As required
35 Single core PVC insulated
Cable
25mm 2 As required
36 DIN rail 35 mm As required
37 PVC type Cable tray 50 mm x 50 mm As required
38 Cable ties 4 ldquo As required
39 Flexible wires 075 mm As required
40 PVC Connectors 5 A amp 20 A 240 V As required
41 Terminal block 20A 240Vac As required
Procedures
5 Identify each component according to specification and quantity required from the schematic
diagram attached
6 Test the functionality of each component by using multi-meter or power supply whichever
applicable
7 Wire component according to circuit diagram
8 Three motors operated in sequence by DOL starter operated by manual push button or time
delay relay
a One loop per-cycle
b Continuous operation in a loop
c optional circuit design to represent the same task
d Only one out of three motors to be operated at a time (quiz)
9 Test the functionality of completed project
80 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
BASIC DESIGN INDUSTRIAL MOTOR CONTROL (SEQUENCE CONTROL)
THREE PHASE INDUCTION MOTOR OPERATED IN SEQUENCE BY DIRECT ON LINE
STARTER
LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
81 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
82 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Lcd lamp indicator 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
11 Overload Relay 415V 20A 3
12 Three phase induction motor 5 hp 3
13 Single phase step down transformer 2500VA 1
14 Single core PVC insulated Cable 1mm 2 As required
15 Single core PVC insulated Cable 25mm 2 As required
16 DIN rail 35 mm As required
17 PVC type Cable tray 50 mm x 50 mm As required
18 Cable ties 4 ldquo As required
19 Flexible wires 1 mm Oslash As required
20 PVC Terminal block 10A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the schematic
diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a optional exercise
i Forward Reverse dahlander motor
4 Test the functionality of completed project
83 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
THREE PHASE DAHLANDER TYPE INDUCTION MOTOR OPERATED FORWARD AND
REVERSE OPERATION BY DIRECT ON LINE STARTER
84 ndash 99EASYTECH ENTERPRISE
LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
Introduction
If a motors windings are connected in the star configuration any two phases will be in series across
the supply and hence the line current will be smaller(by 577) than if the windings were connected in
the delta arrangement
Hence larger-type motors with heavy starting currents are first connected in star and then when the
starting currents fall in delta This of course means that all six of the ends of the windings must be
brought to terminations outside the casing (Fig 833)
EZTECH
EZTECH ELECTRICAL INSTALLATION GUIDE
The automatic version of this starter incorporates a timing relay which automatically changes the
connections from star to delta Figs 834 and 835 show the wiring and schematic diagrams for a star
delta starter
Objectives
1 Identify component and the specification
2 Design forward reverse star delta starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
2 ndash 99EASYTECH ENTERPRISE
REV -C
LEGENDMCCB Moulded Case Circuit BreakerTOR Thermal Over Load RelayFOW-C Mains Forward ContactorREV-C Mains Reverse ContactorDC Delta ContactorSC Star ContactorS-SW Mains Selector Switch
SC
V2
W2
U2
DC
V1
W1
U1
TOR
TOR
FOW-C
30A MCCB
TOR
MAIN CIRCUIT FORWARD REVERSE STAR DELTA
RYBN S
-SW
3 PHASEINDUCTION MOTOR
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Relay 10 A 240V 3
5 Triple pole Contactor
6 cw NO NC auxiliary contact
240Vac 20 A 4
7 Overload Relay 415 V 1
8 LED indicator 240vac 5 A 4
9 Start stop button 240Vac 5A 2
10 DIN rail 35 mm As required
11 Flexible wires 1 mm As required
12 Single core PVC insulated
wire
25 mm As required
13 Terminal block 20 A As required
14 Squirrel cage motor 5kW 1
15 5 pin plug and socket 415V 20A 1
16 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
3 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
a Manual star delta
b Manual Forward reverse star delta starter
c Automatic star delta starter
d Automatic Forward reverse star delta starter
4 Test the functionality of completed project
4 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
Objectives
1 Identify component and the specification
2 Design auto transformer starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
5 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Autotransformer starter is used to start a 3 phase induction motor that has a rating between 10 to 15 hp
6 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Autotransformer set 10Kw 415 V 50 Hz 1
5 Triple pole Contactor 240Vac 4
6 Batten type Lamp holder 240 Vac 105 A 4
7 Start stop button 240Vac 10A 4
8 Filament lamp (Bulb ) 240Vac 40W 4
9 DIN rail 35 mm As required
10 Flexible wires 1 mm As required
7 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
11 Single core PVC insulated
wire
25 mm As required
12 Terminal block 20 A As required
13 Squirrel cage motor 10kW 1
14 5 pin plug and socket 415V 20A 1
15 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a open transient autotransformer starter
b close transient autotransformer starter
c Forward reverse autotransformer starter
4 Test the functionality of completed project
8 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
Objectives
1 Identify component and the specification
2 Design rotor resistance starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
9 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Rotor Resistor set 10kW 1
5 Triple pole Contactor 240Vac 20A 4
6 Indicating light 240vac 5 A 4
7 Start stop push button 240Vac 5A 4
8 DIN rail 35 mm As required
9 Flexible wires 1 mm 2 As required
10 Single core PVC insulated wire 25 mm 2 As required
11 Terminal block 20 A As required
12 Slip Ring motor 10kW 1
13 5 pin round 3 phase socket 415V 20A 1
14 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
10 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
4 Test the functionality of completed project
a Dead circuit test b Life circuit test
5 Measure starting and running Amps
LESSON 16
TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
An installation in general will suffer damage
Damage usually occurs on the electric motor control as follows
1 Damage to the main circuit
2 Damage to the control circuit
The cause of the damage
i Overcurrent overload short circuit
ii Leakage current to ground
iii Equipment malfunction
iv The main control circuit
a Trip of main circuit protection devices fire
b Defect of motor terminal such as short circuit fire loose
v The control circuit is not functioning -
a contactor relay relay time overload relay does not work damaged burned
b Loose cable connection disconnected
Detecting and Repairing Damage
Examples of damage are as follows
i Motor does not work
ii Motor function and overload relay trips
iii Motor function but only partially functional control circuit
Methods of detecting damage
Among the known methods necessary to detect damage are as follows
1 Turn off the electricity at the main switch (main switch) in order to avoid any danger during the
work carried out to detect damage
2 Check all the protective gear that controls the motor control main circuit
11 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
3 Make sure the damage function control circuit
4 Check the control circuit according to the schematic circuit diagram of the motor control
5 Check the operation of the control circuit
Note
Use wiring that has been installed on the SYSTEM OF MOTOR CONTROL BOARD by Forward
Reverse control circuit for Star Delta to test and look for damage
SELF-ASSESSMENT QUESTIONS
1 (a) Explain what is meant by the term lsquoback emfrsquo in a motor
(b) Outline the basic differences between series shunt and compound wound dc motors
2 (a) With the aid of diagrams explain how the speed of series shunt and compound-wound motors
may be controlled
(b) A 440V dc shunt-wound motor has a field resistance of 200R and an armature resistance of 06 R
When its speed is 20 rev d second the current drawn from the supply is 122A Calculate its back
emf at this speed If the speed were decreased to 19 revssecond the field flux remaining unchanged
calculate the new back emf and the new armature current
3 A load of 64 kW at 240 V is supplied from the terminals of a shunt-wound dc generator The field
resistance is 180 A Calculate the armature current
4 (a) Explain with the aid of a diagram how a rotating magnetic field may be
(b) What is meant by lsquosynchronous speedrsquo
Calculate the synchronous obtained speed of a 12 pole motor if the supply frequency is 50Hz
5 (a) Explain the action of a synchronous motor
(b) What methods are available to start a synchronous motor Explain with diagrams
6 (a) Explain the action of a cage induction motor
(b) What is meant by the term lsquosliprsquo
Calculate the percentage slip of a six pole induction motor running at 162 revssecond from a 50 Hz
supply
7 Describe with sketches three different ways of starting a single-phase induction motor
12 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
8 Explain with the aid of a sketch the action of a three-phase DOL starter
What are dashpots used for How are remote start and stop buttons connected
9 A I0 kW 240V 50Hz single-phase cage rotor induction motor is 85efficient and has a PF of 068
lagging Calculate the motor current and the value of capacitor required to raise the PF to 093
lagging
10 Calculate the torque developed by an 18 kW four-pole induction motor run at 35 slip from a
50Hz supply
APPENDIX 1
13 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 11
14 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 111
Attachment Reference
httpswwwtlc-directcoukBook621htm
httpwwwstgovmyindexphpms
15 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
In the windings means that the overload is placed after the point where the wiring to the contactors
are split into main and delta The overload then always measures the current inside the windings
The setting of Overload Relay (In Winding) =058 X FLC (line current)
Disadvantage We must use separate short circuit and overload protections
(2) Size of Main and Delta Contractor
1 There are two contactors that are close during run often referred to as the main contractor and
the delta contactor These are AC3 rated at 58 of the current rating of the motor
Size of Main Contactor= IFL x 058
(3) Size of Star Contractor
The third contactor is the star contactor and that only carries star current while the motor is
connected in star The current in star is 1 radic3= (58) of the current in delta so this contactor can
be AC3 rated at one third (33) of the motor rating
Size of Star Contactor= IFL x 033
Motor Starting Characteristics of Star-Delta Starter
Available starting current 33 Full Load Current
Peak starting current 13 to 26 Full Load Current
Peak starting torque 33 Full Load Torque
Advantages of Star-Delta starter
The operation of the star-delta method is simple and rugged
It is relatively cheap compared to other reduced voltage methods
Good TorqueCurrent Performance
It draws 2 times starting current of the full load ampere of the motor connected
Disadvantages of Star-Delta starter
Low Starting Torque (Torque = (Square of Voltage) is also reduce)
Break In Supply ndash Possible Transients
Six Terminal Motor Required (Delta Connected)
It requires 2 set of cables from starter to motor
It provides only 33 starting torque and if the load connected to the subject motor requires higher
starting torque at the time of starting than very heavy transients and stresses are produced while
changing from star to delta connections and because of these transients and stresses many
electrical and mechanical break-down occurs
26 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
In this method of starting initially motor is connected in star and then after change over the motor
is connected in delta The delta of motor is formed in starter and not on motor terminals
High transmission and current peaks When starting up pumps and fans for example the load
torque is low at the beginning of the start and increases with the square of the speed When
reaching approx 80-85 of the motor rated speed the load torque is equal to the motor torque and
the acceleration ceases To reach the rated speed a switch over to delta position is necessary and
this will very often result in high transmission and current peaks In some cases the current peak
can reach a value that is even bigger than for a DOL start
Applications with a load torque higher than 50 of the motor rated torque will not be able to start
using the start-delta starter
Low Starting Torque The star-delta (wye-delta) starting method controls whether the lead
connections from the motor are configured in a star or delta electrical connection The initial
connection should be in the star pattern that results in a reduction of the line voltage by a factor of
1radic3 (577) to the motor and the current is reduced to 13 of the current at full voltage but the
starting torque is also reduced 13 to 15 of the DOL starting torque
The transition from star to delta transition usually occurs once nominal speed is reached but is
sometimes performed as low as 50 of nominal speed which make transient Sparks
Features of star-delta starting
1 For low- to high-power three-phase motors
2 Reduced starting current
3 Six connection cables
4 Reduced starting torque
5 Current peak on changeover from star to delta
6 Mechanical load on changeover from star to delta
Application of Star-Delta Starter
The star-delta method is usually only applied to low to medium voltage and light starting
Torque motors
The received starting current is about 30 of the starting current during direct on line start and the
starting torque is reduced to about 25 of the torque available at a DOL start This starting
method only works when the application is light loaded during the start If the motor is too heavily
27 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
loaded there will not be enough torque to accelerate the motor up to speed before switching over
to the delta position
LESSON 1 WIRING SYSTEM OF SINGLE PHASE DISTRIBUTION BOARD
Introduction
28 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
29 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
30 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
31 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 2 WIRING SYSTEM OF SINGLE PHASE LIGHTING CIRCUIT Introduction
Objectives
1 Identify component and the specification
2 Wire component according to the schematic diagram
3 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Wiring bay Perforated metal 180 cm x 180 cm 1
2 Cut out fuse 63 A 240 V 1
3 Neutral link 1
4 Single pole one way switch cw
switch box
5A 240Vac 4
5 single pole two way switch cw
switch box
5A 240Vac 2
6 RCCB In = 40 A Tripping current
100mA240 Vac 50 Hz
1
7 Main switch 32 A 240V 1
8 kWatthour meter 40 A 240 Vac 1
9 Single pole MCB 6A 240 Vac 1
10 Self tapping Wood screw As required
11 DIN rail 35 mm width As required
32 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
12 PVC trunking 50 mm x 50 mm As required
13 Terminal blocks 5 A As required
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
1 One way switch to control one lamp
2 One way switch to control two lamps
3 Two of two way switch to control one lamp
4 Two of single pole two way switch and one of an intermediate switch to control one
lamp
5 One unit of ceiling fan and fan regulator to be controlled by one way switch
4 Test the functionality of completed project
LESSON 3ndash WIRING SYSTEM OF SINGLE PHASE POWER CIRCUIT Introduction
33 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
34 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify types of component and its specification
2 Wire component according to the schematic diagram given
3 Test the functionality of the circuit dead circuit test life circuit test
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board Perforated Metal 1
2 kWh meter 240 V 40 A 1
3 Socket outlet 13A 240Vac 4
4 RCCB 40A Trip Amps
30mA240 Vac
1
5 3 pin socket 240Vac 13A 4
6 Single pole MCB 20A 240 V 2
7 DOL starter 1 kW 240Vac 2
8 1 phase induction motor 2Hp 240 Vac 1
9 Cooker control unit 4kW 240Vac 1
10 Water heater point 4kW 240 Vac 1
11 DIN rail 35 mm As required
12 PVC casing 20mm As required
13 Flexible wires 05 mm As required
14 Terminal block 10 A As required
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Wire two unit of 13 A socket outlet in radial circuit
3 Wire four units of 13 A socket outlet in ring circuit
4 Wire one unit DOL starter for air-conditioner point
5 Wire one unit of cooker control unit point
6 Wire one unit of water heater point
7 Test the functionality of each component by using mmeter or power supply whichever
applicable
8 Wire component according to circuit diagram
9 Test the functionality of completed project dead circuit test life circuit test
Note
35 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Ensure that the correct rating of protection device and size of wire used
LESSON 4ndash CONDUIT BENDING AND TRUNKING FABRICATION TECHNIQUE
Common fitting used in an industrial wiring
Cutting and threading the condute
36 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
37 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
38 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify conduit fitting and the specification
2 Measure and Cut steel conduit according to specified dimension
3 Bend and fabricate conduit at 45 90 according to layout diagram
4 Wire component according to the schematic diagram
5 Test the functionality of the circuit
39 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Conduit Bender Oslash 19 mm ( frac34 ldquo) 1
2 Measuring Tape 3 metre 1
3 Hacksaw frame and blade 30cm 1
4 Conduit cutter 1
5 Pipe Vise 1
6 Pipe Wrench 1
7 Ratchet Dies 20 mm 1
8 Metal trunking 50 mm x 50 mm 1
9 GI conduit 20mm 1
10 End box 20 mm 1
11 Flexible wires 05 mm As required
12 Connectors 5 A As required
13 Single core PVC ins Cable 25 mm 2 As required
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Wire two unit of 13 A socket outlet in radial circuit
3 Wire four unit of 13 A socket outlet in ring circuit
4 Wire one unit DOL starter for air-conditioner point
5 Wire one unit of cooker control unit point
6 Wire one unit of water heater point
7 Test the functionality of each component by using multimeter or power supply whichever
applicable
8 Wire component according to circuit diagram
9 Test the functionality of completed project
Note
Ensure that the rating of protection device and size of wire
K prior to 31 March
2004 (BS 7671)
(formerly)
bare conductor
sleeved at terminations (formerly)
40 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 5 ndashWIRING SYSTEM OF 1 Oslash LIGHTING AND POWER CIRCUIT
POWER CIRCUITSa Radial circuits
Radial circuits are arranged in the same way as item 1 above in lighting layouts in that each socket
outlet is supplied via the previous one
Points to note
1 The number of socket outlets complying with BS 1363 is unlimited for a floor area of up to 50m 2 if
the circuit protection is a 30 A or 32 A cartridge fuse or circuit breaker the cable being 4 mm PVC
copper or 25 mm2 mineral insulated (mi)
2 The number of socket outlets is unlimited for a floor area up to 20 m 2 with any type of circuit
protection of 20 A using 25 mm2 PVC copper cable or 15 mm2 mi
3 The total number of fused spurs is unlimited
b ring final circuits
These circuits are the same as radial circuits except that the final socket outlet is wired back to the
supply position In effect any outlet is supplied from two directions (Fig 152)
Points to note
1 Every twin-socket outlet counts as two single-socket outlets
2 The number of non-fused spurs must not exceed the total number of points on the ring Fig 158
shows seven points on the ring and five spurs
3 The fuse rating of a fused spur box must not exceed 13 A and the current rating of all points supplied
by the fused spur must not exceed 13 A
4 Non-fused spurs must supply no more than one single or one double socket on the ring Fig 158
shows seven points on the ring and five spurs rating of all points supplied by the fused spur must not
exceed 13 A or one stationary appliance
CapacityMain conductor size
copper (mm2)
Earth conductor
size (mm2)
Circuit breaker
capacity (A)
Up to 600 W 15 15 6
600ndash1200 W 1525 15 10
1200ndash1800 W 254 25 16
41 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Ring circuit
(floor area 100 m2)25 15 3032
A2 radial circuit
(floor area 75 m2)40 25 3032
A3 radial circuit
(floor area 50 m2)25 15 20
Air conditioner (15 tonne) 60 60 3032
Cooker 60 60 3032
Water heater 40 40 20
Objectives
1 Identify component and the specification
2 Wire component according to the schematic diagram
3 Test the functionality of the circuit
42 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board Perforated 1
2 Cut out fuse and neutral link 60A 240V 1each
3 kWh meter 240V 40A 1
4 Switched Socket outlet 13A 240Vac 4
5 Single pole two way switch cw switch
box
5A 240Vac 2
6 RCCB ELCB 63 A Tripping current 100mA
415 Vac
1
7 3 pin plug 240Vac 13A 4
8 Single pole MCB 20 A 2
9 Single pole MCB 6A 1
10 Single pole MCB 20A 2
11 DOL starter 240Vac 2
12 1 phase induction motor 2hp 240 Vac 1
13 Self tapping Wood screw As required
14 DIN rail Stainless steel allum35 mm As required
15 PVC pipe 20mm dia As required
16 End box 20 mm dia 4
17 Flexible wires 05 mm 2 As required
18 Connectors 5 A As required
Procedures
43 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
4 Test the functionality of completed project
LESSON 6 ndash WIRING SYSTEM OF 3 Oslash DISTRIBUTION BOARD
Introduction
44 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
45 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
46 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
47 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
48 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify each component and the specification
2 Wire component according to the schematic diagram given
3 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting Board 450 x 600 mm Perforated metal 1
2 5 pin round socket and plug 415V ac 32A 1
3 Cut out fuse 60 A 3
4 Neutral link 1
5 kWatt hour meter 415V 60A 1
6 ELCB RCCB 3P+N In=63A415 Vac I trip= 300mA 1
7 ELCB RCCB 3P+N In=63A415 Vac I trip= 30mA 1
8 Single pole MCB 6A 240 V 3
9 Single pole MCB 20A 240 V 3
10 DOL starter 20 A 240Vac 2
11 Socket outlet 15 A 240 Vac 1
12 Switched Socket outlet 13 A 240 Vac 3
13 Led indicating light 5A 240 Vac 3
14 Single pole 4 gang 1 way switch 5A 240 Vac 2
15 Single pole 2 way switch 5A 240 Vac 2
16 1 phase induction motor 1 kW 240Vac 1
17 Metal trunking 30 mm x30 mm As required
18 Self tapping Wood screw 4 mm x 20 mm As required
19 DIN rail 25 mm x 1mm
20 GI steel rigid conduit 20mm As required
21 Flexible conduit 20mm As required
22 End box 20 mm 4
23 Flexible wires 05 mm 2 As required
24 Single core PVC insulated wire 15 mm 2 As required
25 Single core PVC insulated wires 25 mm 2 As required
26 Terminal block 10 A As required
Procedures
49 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify each components and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
4 Test the functionality of completed project
1 dead circuit test
2 life circuit
Note Proper earthing should be made
50 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 7 ndash WIRING SYSTEM OF THREE PHASE LIGHTING AND POWER CIRCUIT
51 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
52 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify component and the specification
2 Wire component according to the schematic diagram
3 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting bay Board Perforated metal 180 cm x 180 cm 1
2 k Watt hour meter 415V 60A 1
3 MCCB 415V 60A
4 ELCB RCCB In=60A415 Vac I trip=30mA 1
5 5 pin round Socket and
plug
415Vac 32A 4
6 Single pole MCB 6A 1
7 Triple pole MCB 20A 2
8 Triple pole Main switch 60A 1
9 DOL starter 240Vac 2
10 3 phase induction motor 2hp 415 Vac 1
11 1 phase induction motor 1
12 Metal trunking 30 mm x30 mm As required
13 Self tapping Wood screw 4 mm x 20 mm As required
14 DIN rail 25 mm x 1mm
15 GI steel rigid conduit 20mm As required
16 Flexible conduit 20mm As required
17 End box 20 mm 4
18 Flexible wires 05 mm As required
19 Connectors 10 A As required
Procedures
1 Identify each components and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
4 Test the functionality of completed project
1 dead circuit 2 life circuit test
5 Record the current drawn by the load as connected in star and delta
Note Proper earthing should be made
53 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 8 INSPECTION AND TESTING OF ELECTRICAL INSTALLATION
On completion of a wiring installation a number of tests on the installation have to be conducted to
ascertain that the wiring circuits and connected appliances are safe for use Prior to carrying out the
tests an inspection has to be done The results of the inspectionsupervision and test have to be
presented in Form G (as in Appendix IV) and Form H (as in Appendix V)
To have the test certification as in Form H the following tests shall be conducted
i Continuity Test
ii Insulation Resistance Test
iii Polarity Test
iv Earth Electrode Resistance test and
v Residual Current Device Test
1 Continuity Test
There are 3 main types of continuity tests for the final circuits-
i Protection Conductor Continuity Test
ii Final Ring Circuit Conductor Continuity Test
iii Live and Neutral Conductor Continuity Test
a) Protection Conductor Continuity Test
bull To ascertain that all protection conductors are connected in the correct and effective manner
bull Test equipment ndash Multimeter (Ohm range) or Ohm meter
54 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
bull Test Method
1 1048766 Ensure that the main switch RCD and MCB are open circuited (switched off) and all loads
are disconnected
2 1048766 Connected the test leads as in the Figure 81 The meter reading shall be less than 1 Ω
55 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Final Ring Circuit Conductor Continuity Test
bull To ensure that all conductors around the ring circuit have continuity
bull Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
bull Test Method
1 1048766 Disconnect both the supply source live conductors from the MCB the neutral conductor
from the neutral terminals and the earth conductor from the earth terminal in the distribution
fuse box
2 1048766 Connect the test leads as in the Figure 82 (EE)
3 1048766 Repeat the procedure for (L-L) and (N-N)
4 1048766 The meter reading value shall be less than 1 ohm
56 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Live and Neutral Conductor Continuity Test
a To ensure that each conductor in the circuit has continuity
b Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
2 Test Method
1 1048766 Switch off the Main switch RCD and MCB
2 1048766 Disconnect all loads
3 1048766 Switch on all switches in the circuit
4 1048766 Disconnect the fusesfinal circuit breakers and close the circuit
5 1048766 Carry out the test as shown in Figure 83
6 1048766 The meter reading value shall be less than 1Ω
57 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
58 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
CONTINUITY TEST
Insulation Resistance Test
i Ensure that there is no leakage current between phase conductors phase and neutral conductors and
phase conductor and earth
ii Test the strength of the cable insulation
iii Test Equipment ndash Insulation Resistance Tester operating voltage is 250VDC or 500VDC
iv Test Method
1 1048766 Switch off main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
59 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
4 1048766 Carry out test as in the Table below
5 1048766 Meter reading value shall be less than 1 Megaohm
60 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
61 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Insulation resitance test
62 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
INSULATION RESISTANCE TEST BETWEEN CONDUCTORS AND OPPOSITE POLARITY
Polarity Testi Ensure that each fuse or single pole control and protection device is connected only in the phase
conductor
ii Intermediate contact of Edison screw lamp holder is connected to the phase conductor
iii Ensure that phase neutral and earth conductors at socket outlets are connected at the correct
terminals
iv Test Equipment ndash Multimeter (Ohm range) or Ohm meter
v Test Method
1 1048766 Switch off Main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in Figure 85
63 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
5 1048766 Test switches and single phase control devices at the phase conductors
6 1048766 Test socket outlet connection sources
7 1048766 Test Edison screw lamp holder connections
8 1048766 Meter reading value shall be less than 1 Ω
64 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Polarity test
65 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Earth Electrode Resistance Testi To test the earth electrode resistance
ii To ascertain the suitability of the location of the electrode
iii To ensure that the electrode is not buried within the resistance area of another electrode
iv Test equipment ndash Earth Resistance Tester
v Test method -
1 1048766 Terminal rsquoErsquo is connected to the electrode to be tested (green conductor)
2 1048766 Terminal lsquoPrsquo is connected to the potential spike (yellow conductor) at a distance of 10
meters from the earth electrode
3 1048766 Terminal lsquoCrsquo is connected to the current spike (red conductor) at a distance of 20 meters
from the earth electrode
Earth Electrode Resistance Measurement Method (Figure 86)
This test must be repeated at least three times to ensure that the reading is not affected by interacting
earthing regions
i Record the first reading (Z1) Example Z1 = 10 Ω
ii Move the voltage spike to a distance of 6 meters from the original position Record the second
reading (Z2 ) Example Z2 = 10 Ω
iii Move the voltage spike to a distance of 6 meters from the original position Record the third
reading (Z3) Example Z3 = 10 Ω
66 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Residual Current Device Testi Ensure that the residual current device (RCD) trips within the set time on the occurrence of current
leakage to earth
ii Test Equipment ndash RCD Tester RCCB Tester
iii Test Method 1
1 1048766 Use the Trip Test Button
2 1048766 Press the trip button found on the RCD to determine if it trips or otherwise This test would
not be able to determine the sensitivity of the RCD nor the time taken for it to trip
iv Test Method 2
i 1048766 Use a RCD Tester
ii This equipment is equipped with a 13A plug which can be connected to a 13A socket outlet
Select the RCD sensitivity to be the same as the sensitivity of the RCD to be tested to
determine if the RCD can trip The time to trip shall not exceed 40 mS
iii 1048766 Test method ndash
a) Position the selection switch in accordance with the sensitivity of the RCD used
Example 100 mA 01 A
b) Position the operations switch to lsquoNo Triprsquo (frac12 Rated mA = 50) connect the 3 pin plug to
the 13A socket outlet
67 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
c) Switch on the 13A socket outlet ndash ensure that the P-N and P-E lights light up
This shows that the polarity is correct (Note if both the lights as above do not light up the test cannot
be continued)
d) Press the test button ndash the reading shows less than 200 mS and simultaneously the lsquotestrsquo light lights
up and the P-N and P-E lights do not light up At that instant the RCD will not trip
e) Move the selection switch to 180o (+ve wave) ndash repeat steps (d) and (e) Move the operations
switch to lsquoTriprsquo (Rated mA = 100)
g) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200mS
h) Move the selection switch to 0o (-ve wave)
i) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
j) The above test is repeated until a near correct reading is obtained
k) Record the test results
l) Change the operations switch to lsquoFast Triprsquo and press the test button ndash RCD will trip within a
time not exceeding 40 millisecond
m) Repeat a number of times at 0o or 180o
On completion of a wiring installation a number of tests on the installation have to be conducted to
ascertain that the wiring circuits and connected appliances are safe for use Prior to carrying out the
tests an inspection has to be done the following tests shall be conducted
i Continuity Test
ii Insulation Resistance Test
iii Polarity Test
iv Earth Electrode Resistance test and
v Residual Current Device Test
821 Continuity Test
There are 3 main types of continuity tests for the final circuits-
i Protection Conductor Continuity Test
ii Final Ring Circuit Conductor Continuity Test
68 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
iii Live and Neutral Conductor Continuity Test
a) Protection Conductor Continuity Test
bull To ascertain that all protection conductors are connected in the correct and effective manner
bull Test equipment ndash Multimeter (Ohm range) or Ohm meter
bull Test Method
1 1048766 Ensure that the main switch RCD and MCB are open circuited (switched off) and all loads are
disconnected
2 1048766 Connected the test leads as in the Figure 81
3 1048766 The meter reading shall be less than 1 Ω
Final Ring Circuit Conductor Continuity Test
bull To ensure that all conductors around the ring circuit have continuity
bull Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
bull Test Method
1 1048766 Disconnect both the supply source live conductors from the MCB the neutral conductor
from the neutral terminals and the earth conductor from the earth terminal in the distribution
fuse box
2 1048766 Connect the test leads as in the Figure 82 (EE)
3 1048766 Repeat the procedure for (L-L) and (N-N)
4 1048766 The meter reading value shall be less than 1 ohm Figure 82 - Final Ring Circuit Conductor
Continuity Test Ohm Meter
Disconnect both the supply source cables from mcbfuse
Take readings at earth conductors of both sources and note resistance readings
Live and Neutral Conductor Continuity Test
1 To ensure that each conductor in the circuit has continuity
2 Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
3 Test Method
1 1048766 Switch off the Main switch RCD and MCB
2 1048766 Disconnect all loads
3 1048766 Switch on all switches in the circuit
4 1048766 Disconnect the fusesfinal circuit breakers and close the circuit
5 1048766 Carry out the test as shown in Figure 83
6 1048766 The meter reading value shall be less than 1 ohm Figure 83 - Live and Neutral
Conductor Continuity Test Ohm Meter
Insulation Resistance Test
69 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
i Ensure that there is no leakage current between phase conductors phase and neutral conductors and
phase conductor and earth
ii Test the strength of the cable insulation
iii Test Equipment ndash Insulation Resistance Tester Operating voltage is 250VDC or 500VDC
iv Test Method
1 1048766 Switch off main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in the Table below
5 1048766 Meter reading value shall be less than 1 Megaohm
Polarity Test
i Ensure that each fuse or single pole control and protection device is connected only in the phase
conductor
ii Intermediate contact of Edison screw lamp holder is connected to the phase conductor
iii Ensure that phase neutral and earth conductors at socket outlets are connected at the correct
terminals
iv Test Equipment ndash Multimeter (Ohm range) or Ohm meter
v Test Method
1 1048766 Switch off Main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in Figure 85
5 1048766 Test switches and single phase control devices at the phase conductors
6 1048766 Test socket outlet connection sources
7 1048766 Test Edison screw lamp holder connections
8 1048766 Meter reading value shall be less than 1 Ω
Earth Electrode Resistance Test
i To test the earth electrode resistance
70 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
ii To ascertain the suitability of the location of the electrode
iii To ensure that the electrode is not buried within the resistance area of another electrode
iv Test equipment ndash Earth Resistance Tester
v Test method -
1 1048766 Terminal rsquoErsquo is connected to the electrode to be tested (green conductor)
2 1048766 Terminal lsquoPrsquo is connected to the potential spike (yellow conductor) at a distance of 10
meters from the earth electrode
3 1048766 Terminal lsquoCrsquo is connected to the current spike (red conductor) at a distance of 20 meters
from the earth electrode E P C Electrode 10 meter 10 meter
Figure 86 ndash Earth Electrode Resistance Measurement Test Equipment
Earth Electrode Resistance Measurement Method (Figure 86)
This test must be repeated at least three times to ensure that the reading is not affected by interacting
earthing regions
i Record the first reading (Z1) Example Z1 = 10 Ω
ii Move the voltage spike to a distance of 6 meters from the original position Record the second
reading (Z2) Example Z2 = 10 Ω
iii Move the voltage spike to a distance of 6 meters from the original position Record the third
reading (Z3)
Example Z3 = 10 Ω
Residual Current Device Test
71 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
i Ensure that the residual current device (RCD) trips within the set time on the occurrence of current
leakage to earth
ii Test Equipment ndash RCD Tester RCCB Tester
iii Test Method 1
1 1048766 Use the Trip Test Button
2 1048766 Press the trip button found on the RCD to determine if it trips or otherwise This test would
not be able to determine the sensitivity of the RCD nor the time taken for it to trip
iv Test Method 2
1048766 Use a RCD Tester
This equipment is equipped with a 13A plug which can be connected to a 13A socket outlet Select the
RCD sensitivity to be the same as the sensitivity of the RCD to be tested to determine if the RCD can
trip The time to trip shall not exceed 40 mS
1048766 Test method ndash
a) Position the selection switch in accordance with the sensitivity of the RCD used
Example 100 mA 01 A
b) Position the operations switch to lsquoNo Triprsquo (frac12 Rated mA = 50) connect the 3 pin plug to
the 13A socket outlet
c) Switch on the 13A socket outlet ndash ensure that the P-N and P-E lights light up This shows that
the polarity is correct (Note if both the lights as above do not light up the test cannot be
continued)
d) Press the test button ndash the reading shows less than 200 millisecond and simultaneously the
lsquotestrsquo light lights up and the P-N and P-E lights do not light up At that instant the RCD will
not trip
e) Move the selection switch to 180o (+ve wave) ndash repeat steps (d) and (e) = 100)
f) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
g) Move the selection switch to 0o (-ve wave)
h) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
i) The above test is repeated until a near correct reading is obtained
j) Record the test results
k) Change the operations switch to lsquoFast Triprsquo and press the test button ndash RCD will trip within a
time not exceeding 40 mS
l) Repeat a number of times at 0o or 180o
72 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 9 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (DC)
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
73 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Start stop button 240Vac 5A 2
9 Filament lamp (Bulb ) 240Vac 40W 3
10 Overload Relay 415V 20A 3
11 Three phase induction motor 5 hp 3
12 Single phase step down transformer 2500VA 1
13 Single core PVC insulated Cable 1mm 2 As required
14 Single core PVC insulated Cable 25mm 2 As required
15 DIN rail 35 mm As required
16 PVC type Cable tray 50 mm x 50 mm As required
17 Cable ties 4 ldquo As required
18 Flexible wires 05 mm As required
19 PVC Connectors 5 A amp 20 A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the schematic
diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a optional exercise
i Simple DOL starter
ii Forward reverse DOL starter
iii Forward Reverse Dahlander motor
iv Three motors operated in sequence by DOL starter operated by manual push
button or time delay relay
74 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
a One loop per-cycle
b Continuous operation in a loop
c optional circuit design to represent the same task
v Only one out of three motors to be operated at a time (quiz)
4 Test the functionality of completed project
LESSON 10 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (AC)
75 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 1
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Lamp point 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
76 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
11 Overload Relay 415V 20A 3
12 Three phase induction
motor
5 hp 3
13 Single core PVC insulated
Cable
1mm 2 As required
14 Single core PVC insulated
Cable
25mm 2 As required
15 DIN rail 35 mm As required
16 PVC type Cable tray 50 mm x 50 mm As required
17 Cable ties 4 ldquo As required
18 Flexible wires 05 mm As required
19 PVC Connectors 5 A amp 20 A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the
schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram optional exercise
4 Simple DOL starter
5 Forward reverse DOL starter
6 Test the functionality of completed project
77 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 1
78 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
cm
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Indicating light 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
11 Overload Relay 415V 20A 3
12 Three phase induction motor 5 hp 3
13 Single phase step down
transformer
2500VA 1
14 Single core PVC insulated
Cable
1mm 2 As required
15 Single core PVC insulated
Cable
25mm 2 As required
16 DIN rail 35 mm As required
17 PVC type Cable tray 50 mm x 50 mm As required
18 Cable ties 4 ldquo As required
19 Flexible wires 05 mm As required
20 PVC Connectors 5 A amp 20 A 240 V As required
21 Single pole MCB 6A 240 V 1
22 Single pole MCB 2A 240 V 1
23 Triple pole MCB 20A 415 V 1
24 Mounting board 30 cm x 40 cm x 3
cm
1
25 Relay cw 11 pin socket 10 A 240 Vac 2
26 Time delay relay 10 A 240 Vac 3
27 Triple pole Contactor 20A 240Vac 3
28 Batten type Lamp holder 240Vac 10 A 3
29 Start stop button 240Vac 10A 2
30 Indicating light (Bulb ) 240Vac 25W 3
31 Overload Relay 415V 20A 1
32 Three phase dahlander type
induction motor
5 hp 1
33 Single phase step down
transformer
24024Vac
2500VA
1
79 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
34 Single core PVC insulated
Cable
1mm 2 As required
35 Single core PVC insulated
Cable
25mm 2 As required
36 DIN rail 35 mm As required
37 PVC type Cable tray 50 mm x 50 mm As required
38 Cable ties 4 ldquo As required
39 Flexible wires 075 mm As required
40 PVC Connectors 5 A amp 20 A 240 V As required
41 Terminal block 20A 240Vac As required
Procedures
5 Identify each component according to specification and quantity required from the schematic
diagram attached
6 Test the functionality of each component by using multi-meter or power supply whichever
applicable
7 Wire component according to circuit diagram
8 Three motors operated in sequence by DOL starter operated by manual push button or time
delay relay
a One loop per-cycle
b Continuous operation in a loop
c optional circuit design to represent the same task
d Only one out of three motors to be operated at a time (quiz)
9 Test the functionality of completed project
80 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
BASIC DESIGN INDUSTRIAL MOTOR CONTROL (SEQUENCE CONTROL)
THREE PHASE INDUCTION MOTOR OPERATED IN SEQUENCE BY DIRECT ON LINE
STARTER
LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
81 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
82 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Lcd lamp indicator 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
11 Overload Relay 415V 20A 3
12 Three phase induction motor 5 hp 3
13 Single phase step down transformer 2500VA 1
14 Single core PVC insulated Cable 1mm 2 As required
15 Single core PVC insulated Cable 25mm 2 As required
16 DIN rail 35 mm As required
17 PVC type Cable tray 50 mm x 50 mm As required
18 Cable ties 4 ldquo As required
19 Flexible wires 1 mm Oslash As required
20 PVC Terminal block 10A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the schematic
diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a optional exercise
i Forward Reverse dahlander motor
4 Test the functionality of completed project
83 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
THREE PHASE DAHLANDER TYPE INDUCTION MOTOR OPERATED FORWARD AND
REVERSE OPERATION BY DIRECT ON LINE STARTER
84 ndash 99EASYTECH ENTERPRISE
LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
Introduction
If a motors windings are connected in the star configuration any two phases will be in series across
the supply and hence the line current will be smaller(by 577) than if the windings were connected in
the delta arrangement
Hence larger-type motors with heavy starting currents are first connected in star and then when the
starting currents fall in delta This of course means that all six of the ends of the windings must be
brought to terminations outside the casing (Fig 833)
EZTECH
EZTECH ELECTRICAL INSTALLATION GUIDE
The automatic version of this starter incorporates a timing relay which automatically changes the
connections from star to delta Figs 834 and 835 show the wiring and schematic diagrams for a star
delta starter
Objectives
1 Identify component and the specification
2 Design forward reverse star delta starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
2 ndash 99EASYTECH ENTERPRISE
REV -C
LEGENDMCCB Moulded Case Circuit BreakerTOR Thermal Over Load RelayFOW-C Mains Forward ContactorREV-C Mains Reverse ContactorDC Delta ContactorSC Star ContactorS-SW Mains Selector Switch
SC
V2
W2
U2
DC
V1
W1
U1
TOR
TOR
FOW-C
30A MCCB
TOR
MAIN CIRCUIT FORWARD REVERSE STAR DELTA
RYBN S
-SW
3 PHASEINDUCTION MOTOR
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Relay 10 A 240V 3
5 Triple pole Contactor
6 cw NO NC auxiliary contact
240Vac 20 A 4
7 Overload Relay 415 V 1
8 LED indicator 240vac 5 A 4
9 Start stop button 240Vac 5A 2
10 DIN rail 35 mm As required
11 Flexible wires 1 mm As required
12 Single core PVC insulated
wire
25 mm As required
13 Terminal block 20 A As required
14 Squirrel cage motor 5kW 1
15 5 pin plug and socket 415V 20A 1
16 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
3 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
a Manual star delta
b Manual Forward reverse star delta starter
c Automatic star delta starter
d Automatic Forward reverse star delta starter
4 Test the functionality of completed project
4 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
Objectives
1 Identify component and the specification
2 Design auto transformer starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
5 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Autotransformer starter is used to start a 3 phase induction motor that has a rating between 10 to 15 hp
6 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Autotransformer set 10Kw 415 V 50 Hz 1
5 Triple pole Contactor 240Vac 4
6 Batten type Lamp holder 240 Vac 105 A 4
7 Start stop button 240Vac 10A 4
8 Filament lamp (Bulb ) 240Vac 40W 4
9 DIN rail 35 mm As required
10 Flexible wires 1 mm As required
7 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
11 Single core PVC insulated
wire
25 mm As required
12 Terminal block 20 A As required
13 Squirrel cage motor 10kW 1
14 5 pin plug and socket 415V 20A 1
15 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a open transient autotransformer starter
b close transient autotransformer starter
c Forward reverse autotransformer starter
4 Test the functionality of completed project
8 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
Objectives
1 Identify component and the specification
2 Design rotor resistance starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
9 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Rotor Resistor set 10kW 1
5 Triple pole Contactor 240Vac 20A 4
6 Indicating light 240vac 5 A 4
7 Start stop push button 240Vac 5A 4
8 DIN rail 35 mm As required
9 Flexible wires 1 mm 2 As required
10 Single core PVC insulated wire 25 mm 2 As required
11 Terminal block 20 A As required
12 Slip Ring motor 10kW 1
13 5 pin round 3 phase socket 415V 20A 1
14 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
10 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
4 Test the functionality of completed project
a Dead circuit test b Life circuit test
5 Measure starting and running Amps
LESSON 16
TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
An installation in general will suffer damage
Damage usually occurs on the electric motor control as follows
1 Damage to the main circuit
2 Damage to the control circuit
The cause of the damage
i Overcurrent overload short circuit
ii Leakage current to ground
iii Equipment malfunction
iv The main control circuit
a Trip of main circuit protection devices fire
b Defect of motor terminal such as short circuit fire loose
v The control circuit is not functioning -
a contactor relay relay time overload relay does not work damaged burned
b Loose cable connection disconnected
Detecting and Repairing Damage
Examples of damage are as follows
i Motor does not work
ii Motor function and overload relay trips
iii Motor function but only partially functional control circuit
Methods of detecting damage
Among the known methods necessary to detect damage are as follows
1 Turn off the electricity at the main switch (main switch) in order to avoid any danger during the
work carried out to detect damage
2 Check all the protective gear that controls the motor control main circuit
11 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
3 Make sure the damage function control circuit
4 Check the control circuit according to the schematic circuit diagram of the motor control
5 Check the operation of the control circuit
Note
Use wiring that has been installed on the SYSTEM OF MOTOR CONTROL BOARD by Forward
Reverse control circuit for Star Delta to test and look for damage
SELF-ASSESSMENT QUESTIONS
1 (a) Explain what is meant by the term lsquoback emfrsquo in a motor
(b) Outline the basic differences between series shunt and compound wound dc motors
2 (a) With the aid of diagrams explain how the speed of series shunt and compound-wound motors
may be controlled
(b) A 440V dc shunt-wound motor has a field resistance of 200R and an armature resistance of 06 R
When its speed is 20 rev d second the current drawn from the supply is 122A Calculate its back
emf at this speed If the speed were decreased to 19 revssecond the field flux remaining unchanged
calculate the new back emf and the new armature current
3 A load of 64 kW at 240 V is supplied from the terminals of a shunt-wound dc generator The field
resistance is 180 A Calculate the armature current
4 (a) Explain with the aid of a diagram how a rotating magnetic field may be
(b) What is meant by lsquosynchronous speedrsquo
Calculate the synchronous obtained speed of a 12 pole motor if the supply frequency is 50Hz
5 (a) Explain the action of a synchronous motor
(b) What methods are available to start a synchronous motor Explain with diagrams
6 (a) Explain the action of a cage induction motor
(b) What is meant by the term lsquosliprsquo
Calculate the percentage slip of a six pole induction motor running at 162 revssecond from a 50 Hz
supply
7 Describe with sketches three different ways of starting a single-phase induction motor
12 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
8 Explain with the aid of a sketch the action of a three-phase DOL starter
What are dashpots used for How are remote start and stop buttons connected
9 A I0 kW 240V 50Hz single-phase cage rotor induction motor is 85efficient and has a PF of 068
lagging Calculate the motor current and the value of capacitor required to raise the PF to 093
lagging
10 Calculate the torque developed by an 18 kW four-pole induction motor run at 35 slip from a
50Hz supply
APPENDIX 1
13 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 11
14 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 111
Attachment Reference
httpswwwtlc-directcoukBook621htm
httpwwwstgovmyindexphpms
15 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
In this method of starting initially motor is connected in star and then after change over the motor
is connected in delta The delta of motor is formed in starter and not on motor terminals
High transmission and current peaks When starting up pumps and fans for example the load
torque is low at the beginning of the start and increases with the square of the speed When
reaching approx 80-85 of the motor rated speed the load torque is equal to the motor torque and
the acceleration ceases To reach the rated speed a switch over to delta position is necessary and
this will very often result in high transmission and current peaks In some cases the current peak
can reach a value that is even bigger than for a DOL start
Applications with a load torque higher than 50 of the motor rated torque will not be able to start
using the start-delta starter
Low Starting Torque The star-delta (wye-delta) starting method controls whether the lead
connections from the motor are configured in a star or delta electrical connection The initial
connection should be in the star pattern that results in a reduction of the line voltage by a factor of
1radic3 (577) to the motor and the current is reduced to 13 of the current at full voltage but the
starting torque is also reduced 13 to 15 of the DOL starting torque
The transition from star to delta transition usually occurs once nominal speed is reached but is
sometimes performed as low as 50 of nominal speed which make transient Sparks
Features of star-delta starting
1 For low- to high-power three-phase motors
2 Reduced starting current
3 Six connection cables
4 Reduced starting torque
5 Current peak on changeover from star to delta
6 Mechanical load on changeover from star to delta
Application of Star-Delta Starter
The star-delta method is usually only applied to low to medium voltage and light starting
Torque motors
The received starting current is about 30 of the starting current during direct on line start and the
starting torque is reduced to about 25 of the torque available at a DOL start This starting
method only works when the application is light loaded during the start If the motor is too heavily
27 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
loaded there will not be enough torque to accelerate the motor up to speed before switching over
to the delta position
LESSON 1 WIRING SYSTEM OF SINGLE PHASE DISTRIBUTION BOARD
Introduction
28 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
29 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
30 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
31 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 2 WIRING SYSTEM OF SINGLE PHASE LIGHTING CIRCUIT Introduction
Objectives
1 Identify component and the specification
2 Wire component according to the schematic diagram
3 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Wiring bay Perforated metal 180 cm x 180 cm 1
2 Cut out fuse 63 A 240 V 1
3 Neutral link 1
4 Single pole one way switch cw
switch box
5A 240Vac 4
5 single pole two way switch cw
switch box
5A 240Vac 2
6 RCCB In = 40 A Tripping current
100mA240 Vac 50 Hz
1
7 Main switch 32 A 240V 1
8 kWatthour meter 40 A 240 Vac 1
9 Single pole MCB 6A 240 Vac 1
10 Self tapping Wood screw As required
11 DIN rail 35 mm width As required
32 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
12 PVC trunking 50 mm x 50 mm As required
13 Terminal blocks 5 A As required
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
1 One way switch to control one lamp
2 One way switch to control two lamps
3 Two of two way switch to control one lamp
4 Two of single pole two way switch and one of an intermediate switch to control one
lamp
5 One unit of ceiling fan and fan regulator to be controlled by one way switch
4 Test the functionality of completed project
LESSON 3ndash WIRING SYSTEM OF SINGLE PHASE POWER CIRCUIT Introduction
33 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
34 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify types of component and its specification
2 Wire component according to the schematic diagram given
3 Test the functionality of the circuit dead circuit test life circuit test
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board Perforated Metal 1
2 kWh meter 240 V 40 A 1
3 Socket outlet 13A 240Vac 4
4 RCCB 40A Trip Amps
30mA240 Vac
1
5 3 pin socket 240Vac 13A 4
6 Single pole MCB 20A 240 V 2
7 DOL starter 1 kW 240Vac 2
8 1 phase induction motor 2Hp 240 Vac 1
9 Cooker control unit 4kW 240Vac 1
10 Water heater point 4kW 240 Vac 1
11 DIN rail 35 mm As required
12 PVC casing 20mm As required
13 Flexible wires 05 mm As required
14 Terminal block 10 A As required
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Wire two unit of 13 A socket outlet in radial circuit
3 Wire four units of 13 A socket outlet in ring circuit
4 Wire one unit DOL starter for air-conditioner point
5 Wire one unit of cooker control unit point
6 Wire one unit of water heater point
7 Test the functionality of each component by using mmeter or power supply whichever
applicable
8 Wire component according to circuit diagram
9 Test the functionality of completed project dead circuit test life circuit test
Note
35 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Ensure that the correct rating of protection device and size of wire used
LESSON 4ndash CONDUIT BENDING AND TRUNKING FABRICATION TECHNIQUE
Common fitting used in an industrial wiring
Cutting and threading the condute
36 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
37 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
38 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify conduit fitting and the specification
2 Measure and Cut steel conduit according to specified dimension
3 Bend and fabricate conduit at 45 90 according to layout diagram
4 Wire component according to the schematic diagram
5 Test the functionality of the circuit
39 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Conduit Bender Oslash 19 mm ( frac34 ldquo) 1
2 Measuring Tape 3 metre 1
3 Hacksaw frame and blade 30cm 1
4 Conduit cutter 1
5 Pipe Vise 1
6 Pipe Wrench 1
7 Ratchet Dies 20 mm 1
8 Metal trunking 50 mm x 50 mm 1
9 GI conduit 20mm 1
10 End box 20 mm 1
11 Flexible wires 05 mm As required
12 Connectors 5 A As required
13 Single core PVC ins Cable 25 mm 2 As required
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Wire two unit of 13 A socket outlet in radial circuit
3 Wire four unit of 13 A socket outlet in ring circuit
4 Wire one unit DOL starter for air-conditioner point
5 Wire one unit of cooker control unit point
6 Wire one unit of water heater point
7 Test the functionality of each component by using multimeter or power supply whichever
applicable
8 Wire component according to circuit diagram
9 Test the functionality of completed project
Note
Ensure that the rating of protection device and size of wire
K prior to 31 March
2004 (BS 7671)
(formerly)
bare conductor
sleeved at terminations (formerly)
40 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 5 ndashWIRING SYSTEM OF 1 Oslash LIGHTING AND POWER CIRCUIT
POWER CIRCUITSa Radial circuits
Radial circuits are arranged in the same way as item 1 above in lighting layouts in that each socket
outlet is supplied via the previous one
Points to note
1 The number of socket outlets complying with BS 1363 is unlimited for a floor area of up to 50m 2 if
the circuit protection is a 30 A or 32 A cartridge fuse or circuit breaker the cable being 4 mm PVC
copper or 25 mm2 mineral insulated (mi)
2 The number of socket outlets is unlimited for a floor area up to 20 m 2 with any type of circuit
protection of 20 A using 25 mm2 PVC copper cable or 15 mm2 mi
3 The total number of fused spurs is unlimited
b ring final circuits
These circuits are the same as radial circuits except that the final socket outlet is wired back to the
supply position In effect any outlet is supplied from two directions (Fig 152)
Points to note
1 Every twin-socket outlet counts as two single-socket outlets
2 The number of non-fused spurs must not exceed the total number of points on the ring Fig 158
shows seven points on the ring and five spurs
3 The fuse rating of a fused spur box must not exceed 13 A and the current rating of all points supplied
by the fused spur must not exceed 13 A
4 Non-fused spurs must supply no more than one single or one double socket on the ring Fig 158
shows seven points on the ring and five spurs rating of all points supplied by the fused spur must not
exceed 13 A or one stationary appliance
CapacityMain conductor size
copper (mm2)
Earth conductor
size (mm2)
Circuit breaker
capacity (A)
Up to 600 W 15 15 6
600ndash1200 W 1525 15 10
1200ndash1800 W 254 25 16
41 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Ring circuit
(floor area 100 m2)25 15 3032
A2 radial circuit
(floor area 75 m2)40 25 3032
A3 radial circuit
(floor area 50 m2)25 15 20
Air conditioner (15 tonne) 60 60 3032
Cooker 60 60 3032
Water heater 40 40 20
Objectives
1 Identify component and the specification
2 Wire component according to the schematic diagram
3 Test the functionality of the circuit
42 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board Perforated 1
2 Cut out fuse and neutral link 60A 240V 1each
3 kWh meter 240V 40A 1
4 Switched Socket outlet 13A 240Vac 4
5 Single pole two way switch cw switch
box
5A 240Vac 2
6 RCCB ELCB 63 A Tripping current 100mA
415 Vac
1
7 3 pin plug 240Vac 13A 4
8 Single pole MCB 20 A 2
9 Single pole MCB 6A 1
10 Single pole MCB 20A 2
11 DOL starter 240Vac 2
12 1 phase induction motor 2hp 240 Vac 1
13 Self tapping Wood screw As required
14 DIN rail Stainless steel allum35 mm As required
15 PVC pipe 20mm dia As required
16 End box 20 mm dia 4
17 Flexible wires 05 mm 2 As required
18 Connectors 5 A As required
Procedures
43 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
4 Test the functionality of completed project
LESSON 6 ndash WIRING SYSTEM OF 3 Oslash DISTRIBUTION BOARD
Introduction
44 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
45 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
46 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
47 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
48 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify each component and the specification
2 Wire component according to the schematic diagram given
3 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting Board 450 x 600 mm Perforated metal 1
2 5 pin round socket and plug 415V ac 32A 1
3 Cut out fuse 60 A 3
4 Neutral link 1
5 kWatt hour meter 415V 60A 1
6 ELCB RCCB 3P+N In=63A415 Vac I trip= 300mA 1
7 ELCB RCCB 3P+N In=63A415 Vac I trip= 30mA 1
8 Single pole MCB 6A 240 V 3
9 Single pole MCB 20A 240 V 3
10 DOL starter 20 A 240Vac 2
11 Socket outlet 15 A 240 Vac 1
12 Switched Socket outlet 13 A 240 Vac 3
13 Led indicating light 5A 240 Vac 3
14 Single pole 4 gang 1 way switch 5A 240 Vac 2
15 Single pole 2 way switch 5A 240 Vac 2
16 1 phase induction motor 1 kW 240Vac 1
17 Metal trunking 30 mm x30 mm As required
18 Self tapping Wood screw 4 mm x 20 mm As required
19 DIN rail 25 mm x 1mm
20 GI steel rigid conduit 20mm As required
21 Flexible conduit 20mm As required
22 End box 20 mm 4
23 Flexible wires 05 mm 2 As required
24 Single core PVC insulated wire 15 mm 2 As required
25 Single core PVC insulated wires 25 mm 2 As required
26 Terminal block 10 A As required
Procedures
49 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify each components and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
4 Test the functionality of completed project
1 dead circuit test
2 life circuit
Note Proper earthing should be made
50 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 7 ndash WIRING SYSTEM OF THREE PHASE LIGHTING AND POWER CIRCUIT
51 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
52 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify component and the specification
2 Wire component according to the schematic diagram
3 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting bay Board Perforated metal 180 cm x 180 cm 1
2 k Watt hour meter 415V 60A 1
3 MCCB 415V 60A
4 ELCB RCCB In=60A415 Vac I trip=30mA 1
5 5 pin round Socket and
plug
415Vac 32A 4
6 Single pole MCB 6A 1
7 Triple pole MCB 20A 2
8 Triple pole Main switch 60A 1
9 DOL starter 240Vac 2
10 3 phase induction motor 2hp 415 Vac 1
11 1 phase induction motor 1
12 Metal trunking 30 mm x30 mm As required
13 Self tapping Wood screw 4 mm x 20 mm As required
14 DIN rail 25 mm x 1mm
15 GI steel rigid conduit 20mm As required
16 Flexible conduit 20mm As required
17 End box 20 mm 4
18 Flexible wires 05 mm As required
19 Connectors 10 A As required
Procedures
1 Identify each components and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
4 Test the functionality of completed project
1 dead circuit 2 life circuit test
5 Record the current drawn by the load as connected in star and delta
Note Proper earthing should be made
53 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 8 INSPECTION AND TESTING OF ELECTRICAL INSTALLATION
On completion of a wiring installation a number of tests on the installation have to be conducted to
ascertain that the wiring circuits and connected appliances are safe for use Prior to carrying out the
tests an inspection has to be done The results of the inspectionsupervision and test have to be
presented in Form G (as in Appendix IV) and Form H (as in Appendix V)
To have the test certification as in Form H the following tests shall be conducted
i Continuity Test
ii Insulation Resistance Test
iii Polarity Test
iv Earth Electrode Resistance test and
v Residual Current Device Test
1 Continuity Test
There are 3 main types of continuity tests for the final circuits-
i Protection Conductor Continuity Test
ii Final Ring Circuit Conductor Continuity Test
iii Live and Neutral Conductor Continuity Test
a) Protection Conductor Continuity Test
bull To ascertain that all protection conductors are connected in the correct and effective manner
bull Test equipment ndash Multimeter (Ohm range) or Ohm meter
54 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
bull Test Method
1 1048766 Ensure that the main switch RCD and MCB are open circuited (switched off) and all loads
are disconnected
2 1048766 Connected the test leads as in the Figure 81 The meter reading shall be less than 1 Ω
55 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Final Ring Circuit Conductor Continuity Test
bull To ensure that all conductors around the ring circuit have continuity
bull Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
bull Test Method
1 1048766 Disconnect both the supply source live conductors from the MCB the neutral conductor
from the neutral terminals and the earth conductor from the earth terminal in the distribution
fuse box
2 1048766 Connect the test leads as in the Figure 82 (EE)
3 1048766 Repeat the procedure for (L-L) and (N-N)
4 1048766 The meter reading value shall be less than 1 ohm
56 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Live and Neutral Conductor Continuity Test
a To ensure that each conductor in the circuit has continuity
b Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
2 Test Method
1 1048766 Switch off the Main switch RCD and MCB
2 1048766 Disconnect all loads
3 1048766 Switch on all switches in the circuit
4 1048766 Disconnect the fusesfinal circuit breakers and close the circuit
5 1048766 Carry out the test as shown in Figure 83
6 1048766 The meter reading value shall be less than 1Ω
57 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
58 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
CONTINUITY TEST
Insulation Resistance Test
i Ensure that there is no leakage current between phase conductors phase and neutral conductors and
phase conductor and earth
ii Test the strength of the cable insulation
iii Test Equipment ndash Insulation Resistance Tester operating voltage is 250VDC or 500VDC
iv Test Method
1 1048766 Switch off main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
59 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
4 1048766 Carry out test as in the Table below
5 1048766 Meter reading value shall be less than 1 Megaohm
60 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
61 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Insulation resitance test
62 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
INSULATION RESISTANCE TEST BETWEEN CONDUCTORS AND OPPOSITE POLARITY
Polarity Testi Ensure that each fuse or single pole control and protection device is connected only in the phase
conductor
ii Intermediate contact of Edison screw lamp holder is connected to the phase conductor
iii Ensure that phase neutral and earth conductors at socket outlets are connected at the correct
terminals
iv Test Equipment ndash Multimeter (Ohm range) or Ohm meter
v Test Method
1 1048766 Switch off Main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in Figure 85
63 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
5 1048766 Test switches and single phase control devices at the phase conductors
6 1048766 Test socket outlet connection sources
7 1048766 Test Edison screw lamp holder connections
8 1048766 Meter reading value shall be less than 1 Ω
64 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Polarity test
65 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Earth Electrode Resistance Testi To test the earth electrode resistance
ii To ascertain the suitability of the location of the electrode
iii To ensure that the electrode is not buried within the resistance area of another electrode
iv Test equipment ndash Earth Resistance Tester
v Test method -
1 1048766 Terminal rsquoErsquo is connected to the electrode to be tested (green conductor)
2 1048766 Terminal lsquoPrsquo is connected to the potential spike (yellow conductor) at a distance of 10
meters from the earth electrode
3 1048766 Terminal lsquoCrsquo is connected to the current spike (red conductor) at a distance of 20 meters
from the earth electrode
Earth Electrode Resistance Measurement Method (Figure 86)
This test must be repeated at least three times to ensure that the reading is not affected by interacting
earthing regions
i Record the first reading (Z1) Example Z1 = 10 Ω
ii Move the voltage spike to a distance of 6 meters from the original position Record the second
reading (Z2 ) Example Z2 = 10 Ω
iii Move the voltage spike to a distance of 6 meters from the original position Record the third
reading (Z3) Example Z3 = 10 Ω
66 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Residual Current Device Testi Ensure that the residual current device (RCD) trips within the set time on the occurrence of current
leakage to earth
ii Test Equipment ndash RCD Tester RCCB Tester
iii Test Method 1
1 1048766 Use the Trip Test Button
2 1048766 Press the trip button found on the RCD to determine if it trips or otherwise This test would
not be able to determine the sensitivity of the RCD nor the time taken for it to trip
iv Test Method 2
i 1048766 Use a RCD Tester
ii This equipment is equipped with a 13A plug which can be connected to a 13A socket outlet
Select the RCD sensitivity to be the same as the sensitivity of the RCD to be tested to
determine if the RCD can trip The time to trip shall not exceed 40 mS
iii 1048766 Test method ndash
a) Position the selection switch in accordance with the sensitivity of the RCD used
Example 100 mA 01 A
b) Position the operations switch to lsquoNo Triprsquo (frac12 Rated mA = 50) connect the 3 pin plug to
the 13A socket outlet
67 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
c) Switch on the 13A socket outlet ndash ensure that the P-N and P-E lights light up
This shows that the polarity is correct (Note if both the lights as above do not light up the test cannot
be continued)
d) Press the test button ndash the reading shows less than 200 mS and simultaneously the lsquotestrsquo light lights
up and the P-N and P-E lights do not light up At that instant the RCD will not trip
e) Move the selection switch to 180o (+ve wave) ndash repeat steps (d) and (e) Move the operations
switch to lsquoTriprsquo (Rated mA = 100)
g) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200mS
h) Move the selection switch to 0o (-ve wave)
i) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
j) The above test is repeated until a near correct reading is obtained
k) Record the test results
l) Change the operations switch to lsquoFast Triprsquo and press the test button ndash RCD will trip within a
time not exceeding 40 millisecond
m) Repeat a number of times at 0o or 180o
On completion of a wiring installation a number of tests on the installation have to be conducted to
ascertain that the wiring circuits and connected appliances are safe for use Prior to carrying out the
tests an inspection has to be done the following tests shall be conducted
i Continuity Test
ii Insulation Resistance Test
iii Polarity Test
iv Earth Electrode Resistance test and
v Residual Current Device Test
821 Continuity Test
There are 3 main types of continuity tests for the final circuits-
i Protection Conductor Continuity Test
ii Final Ring Circuit Conductor Continuity Test
68 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
iii Live and Neutral Conductor Continuity Test
a) Protection Conductor Continuity Test
bull To ascertain that all protection conductors are connected in the correct and effective manner
bull Test equipment ndash Multimeter (Ohm range) or Ohm meter
bull Test Method
1 1048766 Ensure that the main switch RCD and MCB are open circuited (switched off) and all loads are
disconnected
2 1048766 Connected the test leads as in the Figure 81
3 1048766 The meter reading shall be less than 1 Ω
Final Ring Circuit Conductor Continuity Test
bull To ensure that all conductors around the ring circuit have continuity
bull Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
bull Test Method
1 1048766 Disconnect both the supply source live conductors from the MCB the neutral conductor
from the neutral terminals and the earth conductor from the earth terminal in the distribution
fuse box
2 1048766 Connect the test leads as in the Figure 82 (EE)
3 1048766 Repeat the procedure for (L-L) and (N-N)
4 1048766 The meter reading value shall be less than 1 ohm Figure 82 - Final Ring Circuit Conductor
Continuity Test Ohm Meter
Disconnect both the supply source cables from mcbfuse
Take readings at earth conductors of both sources and note resistance readings
Live and Neutral Conductor Continuity Test
1 To ensure that each conductor in the circuit has continuity
2 Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
3 Test Method
1 1048766 Switch off the Main switch RCD and MCB
2 1048766 Disconnect all loads
3 1048766 Switch on all switches in the circuit
4 1048766 Disconnect the fusesfinal circuit breakers and close the circuit
5 1048766 Carry out the test as shown in Figure 83
6 1048766 The meter reading value shall be less than 1 ohm Figure 83 - Live and Neutral
Conductor Continuity Test Ohm Meter
Insulation Resistance Test
69 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
i Ensure that there is no leakage current between phase conductors phase and neutral conductors and
phase conductor and earth
ii Test the strength of the cable insulation
iii Test Equipment ndash Insulation Resistance Tester Operating voltage is 250VDC or 500VDC
iv Test Method
1 1048766 Switch off main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in the Table below
5 1048766 Meter reading value shall be less than 1 Megaohm
Polarity Test
i Ensure that each fuse or single pole control and protection device is connected only in the phase
conductor
ii Intermediate contact of Edison screw lamp holder is connected to the phase conductor
iii Ensure that phase neutral and earth conductors at socket outlets are connected at the correct
terminals
iv Test Equipment ndash Multimeter (Ohm range) or Ohm meter
v Test Method
1 1048766 Switch off Main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in Figure 85
5 1048766 Test switches and single phase control devices at the phase conductors
6 1048766 Test socket outlet connection sources
7 1048766 Test Edison screw lamp holder connections
8 1048766 Meter reading value shall be less than 1 Ω
Earth Electrode Resistance Test
i To test the earth electrode resistance
70 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
ii To ascertain the suitability of the location of the electrode
iii To ensure that the electrode is not buried within the resistance area of another electrode
iv Test equipment ndash Earth Resistance Tester
v Test method -
1 1048766 Terminal rsquoErsquo is connected to the electrode to be tested (green conductor)
2 1048766 Terminal lsquoPrsquo is connected to the potential spike (yellow conductor) at a distance of 10
meters from the earth electrode
3 1048766 Terminal lsquoCrsquo is connected to the current spike (red conductor) at a distance of 20 meters
from the earth electrode E P C Electrode 10 meter 10 meter
Figure 86 ndash Earth Electrode Resistance Measurement Test Equipment
Earth Electrode Resistance Measurement Method (Figure 86)
This test must be repeated at least three times to ensure that the reading is not affected by interacting
earthing regions
i Record the first reading (Z1) Example Z1 = 10 Ω
ii Move the voltage spike to a distance of 6 meters from the original position Record the second
reading (Z2) Example Z2 = 10 Ω
iii Move the voltage spike to a distance of 6 meters from the original position Record the third
reading (Z3)
Example Z3 = 10 Ω
Residual Current Device Test
71 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
i Ensure that the residual current device (RCD) trips within the set time on the occurrence of current
leakage to earth
ii Test Equipment ndash RCD Tester RCCB Tester
iii Test Method 1
1 1048766 Use the Trip Test Button
2 1048766 Press the trip button found on the RCD to determine if it trips or otherwise This test would
not be able to determine the sensitivity of the RCD nor the time taken for it to trip
iv Test Method 2
1048766 Use a RCD Tester
This equipment is equipped with a 13A plug which can be connected to a 13A socket outlet Select the
RCD sensitivity to be the same as the sensitivity of the RCD to be tested to determine if the RCD can
trip The time to trip shall not exceed 40 mS
1048766 Test method ndash
a) Position the selection switch in accordance with the sensitivity of the RCD used
Example 100 mA 01 A
b) Position the operations switch to lsquoNo Triprsquo (frac12 Rated mA = 50) connect the 3 pin plug to
the 13A socket outlet
c) Switch on the 13A socket outlet ndash ensure that the P-N and P-E lights light up This shows that
the polarity is correct (Note if both the lights as above do not light up the test cannot be
continued)
d) Press the test button ndash the reading shows less than 200 millisecond and simultaneously the
lsquotestrsquo light lights up and the P-N and P-E lights do not light up At that instant the RCD will
not trip
e) Move the selection switch to 180o (+ve wave) ndash repeat steps (d) and (e) = 100)
f) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
g) Move the selection switch to 0o (-ve wave)
h) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
i) The above test is repeated until a near correct reading is obtained
j) Record the test results
k) Change the operations switch to lsquoFast Triprsquo and press the test button ndash RCD will trip within a
time not exceeding 40 mS
l) Repeat a number of times at 0o or 180o
72 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 9 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (DC)
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
73 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Start stop button 240Vac 5A 2
9 Filament lamp (Bulb ) 240Vac 40W 3
10 Overload Relay 415V 20A 3
11 Three phase induction motor 5 hp 3
12 Single phase step down transformer 2500VA 1
13 Single core PVC insulated Cable 1mm 2 As required
14 Single core PVC insulated Cable 25mm 2 As required
15 DIN rail 35 mm As required
16 PVC type Cable tray 50 mm x 50 mm As required
17 Cable ties 4 ldquo As required
18 Flexible wires 05 mm As required
19 PVC Connectors 5 A amp 20 A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the schematic
diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a optional exercise
i Simple DOL starter
ii Forward reverse DOL starter
iii Forward Reverse Dahlander motor
iv Three motors operated in sequence by DOL starter operated by manual push
button or time delay relay
74 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
a One loop per-cycle
b Continuous operation in a loop
c optional circuit design to represent the same task
v Only one out of three motors to be operated at a time (quiz)
4 Test the functionality of completed project
LESSON 10 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (AC)
75 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 1
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Lamp point 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
76 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
11 Overload Relay 415V 20A 3
12 Three phase induction
motor
5 hp 3
13 Single core PVC insulated
Cable
1mm 2 As required
14 Single core PVC insulated
Cable
25mm 2 As required
15 DIN rail 35 mm As required
16 PVC type Cable tray 50 mm x 50 mm As required
17 Cable ties 4 ldquo As required
18 Flexible wires 05 mm As required
19 PVC Connectors 5 A amp 20 A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the
schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram optional exercise
4 Simple DOL starter
5 Forward reverse DOL starter
6 Test the functionality of completed project
77 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 1
78 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
cm
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Indicating light 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
11 Overload Relay 415V 20A 3
12 Three phase induction motor 5 hp 3
13 Single phase step down
transformer
2500VA 1
14 Single core PVC insulated
Cable
1mm 2 As required
15 Single core PVC insulated
Cable
25mm 2 As required
16 DIN rail 35 mm As required
17 PVC type Cable tray 50 mm x 50 mm As required
18 Cable ties 4 ldquo As required
19 Flexible wires 05 mm As required
20 PVC Connectors 5 A amp 20 A 240 V As required
21 Single pole MCB 6A 240 V 1
22 Single pole MCB 2A 240 V 1
23 Triple pole MCB 20A 415 V 1
24 Mounting board 30 cm x 40 cm x 3
cm
1
25 Relay cw 11 pin socket 10 A 240 Vac 2
26 Time delay relay 10 A 240 Vac 3
27 Triple pole Contactor 20A 240Vac 3
28 Batten type Lamp holder 240Vac 10 A 3
29 Start stop button 240Vac 10A 2
30 Indicating light (Bulb ) 240Vac 25W 3
31 Overload Relay 415V 20A 1
32 Three phase dahlander type
induction motor
5 hp 1
33 Single phase step down
transformer
24024Vac
2500VA
1
79 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
34 Single core PVC insulated
Cable
1mm 2 As required
35 Single core PVC insulated
Cable
25mm 2 As required
36 DIN rail 35 mm As required
37 PVC type Cable tray 50 mm x 50 mm As required
38 Cable ties 4 ldquo As required
39 Flexible wires 075 mm As required
40 PVC Connectors 5 A amp 20 A 240 V As required
41 Terminal block 20A 240Vac As required
Procedures
5 Identify each component according to specification and quantity required from the schematic
diagram attached
6 Test the functionality of each component by using multi-meter or power supply whichever
applicable
7 Wire component according to circuit diagram
8 Three motors operated in sequence by DOL starter operated by manual push button or time
delay relay
a One loop per-cycle
b Continuous operation in a loop
c optional circuit design to represent the same task
d Only one out of three motors to be operated at a time (quiz)
9 Test the functionality of completed project
80 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
BASIC DESIGN INDUSTRIAL MOTOR CONTROL (SEQUENCE CONTROL)
THREE PHASE INDUCTION MOTOR OPERATED IN SEQUENCE BY DIRECT ON LINE
STARTER
LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
81 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
82 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Lcd lamp indicator 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
11 Overload Relay 415V 20A 3
12 Three phase induction motor 5 hp 3
13 Single phase step down transformer 2500VA 1
14 Single core PVC insulated Cable 1mm 2 As required
15 Single core PVC insulated Cable 25mm 2 As required
16 DIN rail 35 mm As required
17 PVC type Cable tray 50 mm x 50 mm As required
18 Cable ties 4 ldquo As required
19 Flexible wires 1 mm Oslash As required
20 PVC Terminal block 10A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the schematic
diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a optional exercise
i Forward Reverse dahlander motor
4 Test the functionality of completed project
83 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
THREE PHASE DAHLANDER TYPE INDUCTION MOTOR OPERATED FORWARD AND
REVERSE OPERATION BY DIRECT ON LINE STARTER
84 ndash 99EASYTECH ENTERPRISE
LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
Introduction
If a motors windings are connected in the star configuration any two phases will be in series across
the supply and hence the line current will be smaller(by 577) than if the windings were connected in
the delta arrangement
Hence larger-type motors with heavy starting currents are first connected in star and then when the
starting currents fall in delta This of course means that all six of the ends of the windings must be
brought to terminations outside the casing (Fig 833)
EZTECH
EZTECH ELECTRICAL INSTALLATION GUIDE
The automatic version of this starter incorporates a timing relay which automatically changes the
connections from star to delta Figs 834 and 835 show the wiring and schematic diagrams for a star
delta starter
Objectives
1 Identify component and the specification
2 Design forward reverse star delta starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
2 ndash 99EASYTECH ENTERPRISE
REV -C
LEGENDMCCB Moulded Case Circuit BreakerTOR Thermal Over Load RelayFOW-C Mains Forward ContactorREV-C Mains Reverse ContactorDC Delta ContactorSC Star ContactorS-SW Mains Selector Switch
SC
V2
W2
U2
DC
V1
W1
U1
TOR
TOR
FOW-C
30A MCCB
TOR
MAIN CIRCUIT FORWARD REVERSE STAR DELTA
RYBN S
-SW
3 PHASEINDUCTION MOTOR
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Relay 10 A 240V 3
5 Triple pole Contactor
6 cw NO NC auxiliary contact
240Vac 20 A 4
7 Overload Relay 415 V 1
8 LED indicator 240vac 5 A 4
9 Start stop button 240Vac 5A 2
10 DIN rail 35 mm As required
11 Flexible wires 1 mm As required
12 Single core PVC insulated
wire
25 mm As required
13 Terminal block 20 A As required
14 Squirrel cage motor 5kW 1
15 5 pin plug and socket 415V 20A 1
16 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
3 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
a Manual star delta
b Manual Forward reverse star delta starter
c Automatic star delta starter
d Automatic Forward reverse star delta starter
4 Test the functionality of completed project
4 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
Objectives
1 Identify component and the specification
2 Design auto transformer starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
5 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Autotransformer starter is used to start a 3 phase induction motor that has a rating between 10 to 15 hp
6 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Autotransformer set 10Kw 415 V 50 Hz 1
5 Triple pole Contactor 240Vac 4
6 Batten type Lamp holder 240 Vac 105 A 4
7 Start stop button 240Vac 10A 4
8 Filament lamp (Bulb ) 240Vac 40W 4
9 DIN rail 35 mm As required
10 Flexible wires 1 mm As required
7 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
11 Single core PVC insulated
wire
25 mm As required
12 Terminal block 20 A As required
13 Squirrel cage motor 10kW 1
14 5 pin plug and socket 415V 20A 1
15 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a open transient autotransformer starter
b close transient autotransformer starter
c Forward reverse autotransformer starter
4 Test the functionality of completed project
8 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
Objectives
1 Identify component and the specification
2 Design rotor resistance starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
9 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Rotor Resistor set 10kW 1
5 Triple pole Contactor 240Vac 20A 4
6 Indicating light 240vac 5 A 4
7 Start stop push button 240Vac 5A 4
8 DIN rail 35 mm As required
9 Flexible wires 1 mm 2 As required
10 Single core PVC insulated wire 25 mm 2 As required
11 Terminal block 20 A As required
12 Slip Ring motor 10kW 1
13 5 pin round 3 phase socket 415V 20A 1
14 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
10 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
4 Test the functionality of completed project
a Dead circuit test b Life circuit test
5 Measure starting and running Amps
LESSON 16
TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
An installation in general will suffer damage
Damage usually occurs on the electric motor control as follows
1 Damage to the main circuit
2 Damage to the control circuit
The cause of the damage
i Overcurrent overload short circuit
ii Leakage current to ground
iii Equipment malfunction
iv The main control circuit
a Trip of main circuit protection devices fire
b Defect of motor terminal such as short circuit fire loose
v The control circuit is not functioning -
a contactor relay relay time overload relay does not work damaged burned
b Loose cable connection disconnected
Detecting and Repairing Damage
Examples of damage are as follows
i Motor does not work
ii Motor function and overload relay trips
iii Motor function but only partially functional control circuit
Methods of detecting damage
Among the known methods necessary to detect damage are as follows
1 Turn off the electricity at the main switch (main switch) in order to avoid any danger during the
work carried out to detect damage
2 Check all the protective gear that controls the motor control main circuit
11 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
3 Make sure the damage function control circuit
4 Check the control circuit according to the schematic circuit diagram of the motor control
5 Check the operation of the control circuit
Note
Use wiring that has been installed on the SYSTEM OF MOTOR CONTROL BOARD by Forward
Reverse control circuit for Star Delta to test and look for damage
SELF-ASSESSMENT QUESTIONS
1 (a) Explain what is meant by the term lsquoback emfrsquo in a motor
(b) Outline the basic differences between series shunt and compound wound dc motors
2 (a) With the aid of diagrams explain how the speed of series shunt and compound-wound motors
may be controlled
(b) A 440V dc shunt-wound motor has a field resistance of 200R and an armature resistance of 06 R
When its speed is 20 rev d second the current drawn from the supply is 122A Calculate its back
emf at this speed If the speed were decreased to 19 revssecond the field flux remaining unchanged
calculate the new back emf and the new armature current
3 A load of 64 kW at 240 V is supplied from the terminals of a shunt-wound dc generator The field
resistance is 180 A Calculate the armature current
4 (a) Explain with the aid of a diagram how a rotating magnetic field may be
(b) What is meant by lsquosynchronous speedrsquo
Calculate the synchronous obtained speed of a 12 pole motor if the supply frequency is 50Hz
5 (a) Explain the action of a synchronous motor
(b) What methods are available to start a synchronous motor Explain with diagrams
6 (a) Explain the action of a cage induction motor
(b) What is meant by the term lsquosliprsquo
Calculate the percentage slip of a six pole induction motor running at 162 revssecond from a 50 Hz
supply
7 Describe with sketches three different ways of starting a single-phase induction motor
12 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
8 Explain with the aid of a sketch the action of a three-phase DOL starter
What are dashpots used for How are remote start and stop buttons connected
9 A I0 kW 240V 50Hz single-phase cage rotor induction motor is 85efficient and has a PF of 068
lagging Calculate the motor current and the value of capacitor required to raise the PF to 093
lagging
10 Calculate the torque developed by an 18 kW four-pole induction motor run at 35 slip from a
50Hz supply
APPENDIX 1
13 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 11
14 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 111
Attachment Reference
httpswwwtlc-directcoukBook621htm
httpwwwstgovmyindexphpms
15 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
loaded there will not be enough torque to accelerate the motor up to speed before switching over
to the delta position
LESSON 1 WIRING SYSTEM OF SINGLE PHASE DISTRIBUTION BOARD
Introduction
28 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
29 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
30 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
31 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 2 WIRING SYSTEM OF SINGLE PHASE LIGHTING CIRCUIT Introduction
Objectives
1 Identify component and the specification
2 Wire component according to the schematic diagram
3 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Wiring bay Perforated metal 180 cm x 180 cm 1
2 Cut out fuse 63 A 240 V 1
3 Neutral link 1
4 Single pole one way switch cw
switch box
5A 240Vac 4
5 single pole two way switch cw
switch box
5A 240Vac 2
6 RCCB In = 40 A Tripping current
100mA240 Vac 50 Hz
1
7 Main switch 32 A 240V 1
8 kWatthour meter 40 A 240 Vac 1
9 Single pole MCB 6A 240 Vac 1
10 Self tapping Wood screw As required
11 DIN rail 35 mm width As required
32 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
12 PVC trunking 50 mm x 50 mm As required
13 Terminal blocks 5 A As required
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
1 One way switch to control one lamp
2 One way switch to control two lamps
3 Two of two way switch to control one lamp
4 Two of single pole two way switch and one of an intermediate switch to control one
lamp
5 One unit of ceiling fan and fan regulator to be controlled by one way switch
4 Test the functionality of completed project
LESSON 3ndash WIRING SYSTEM OF SINGLE PHASE POWER CIRCUIT Introduction
33 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
34 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify types of component and its specification
2 Wire component according to the schematic diagram given
3 Test the functionality of the circuit dead circuit test life circuit test
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board Perforated Metal 1
2 kWh meter 240 V 40 A 1
3 Socket outlet 13A 240Vac 4
4 RCCB 40A Trip Amps
30mA240 Vac
1
5 3 pin socket 240Vac 13A 4
6 Single pole MCB 20A 240 V 2
7 DOL starter 1 kW 240Vac 2
8 1 phase induction motor 2Hp 240 Vac 1
9 Cooker control unit 4kW 240Vac 1
10 Water heater point 4kW 240 Vac 1
11 DIN rail 35 mm As required
12 PVC casing 20mm As required
13 Flexible wires 05 mm As required
14 Terminal block 10 A As required
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Wire two unit of 13 A socket outlet in radial circuit
3 Wire four units of 13 A socket outlet in ring circuit
4 Wire one unit DOL starter for air-conditioner point
5 Wire one unit of cooker control unit point
6 Wire one unit of water heater point
7 Test the functionality of each component by using mmeter or power supply whichever
applicable
8 Wire component according to circuit diagram
9 Test the functionality of completed project dead circuit test life circuit test
Note
35 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Ensure that the correct rating of protection device and size of wire used
LESSON 4ndash CONDUIT BENDING AND TRUNKING FABRICATION TECHNIQUE
Common fitting used in an industrial wiring
Cutting and threading the condute
36 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
37 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
38 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify conduit fitting and the specification
2 Measure and Cut steel conduit according to specified dimension
3 Bend and fabricate conduit at 45 90 according to layout diagram
4 Wire component according to the schematic diagram
5 Test the functionality of the circuit
39 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Conduit Bender Oslash 19 mm ( frac34 ldquo) 1
2 Measuring Tape 3 metre 1
3 Hacksaw frame and blade 30cm 1
4 Conduit cutter 1
5 Pipe Vise 1
6 Pipe Wrench 1
7 Ratchet Dies 20 mm 1
8 Metal trunking 50 mm x 50 mm 1
9 GI conduit 20mm 1
10 End box 20 mm 1
11 Flexible wires 05 mm As required
12 Connectors 5 A As required
13 Single core PVC ins Cable 25 mm 2 As required
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Wire two unit of 13 A socket outlet in radial circuit
3 Wire four unit of 13 A socket outlet in ring circuit
4 Wire one unit DOL starter for air-conditioner point
5 Wire one unit of cooker control unit point
6 Wire one unit of water heater point
7 Test the functionality of each component by using multimeter or power supply whichever
applicable
8 Wire component according to circuit diagram
9 Test the functionality of completed project
Note
Ensure that the rating of protection device and size of wire
K prior to 31 March
2004 (BS 7671)
(formerly)
bare conductor
sleeved at terminations (formerly)
40 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 5 ndashWIRING SYSTEM OF 1 Oslash LIGHTING AND POWER CIRCUIT
POWER CIRCUITSa Radial circuits
Radial circuits are arranged in the same way as item 1 above in lighting layouts in that each socket
outlet is supplied via the previous one
Points to note
1 The number of socket outlets complying with BS 1363 is unlimited for a floor area of up to 50m 2 if
the circuit protection is a 30 A or 32 A cartridge fuse or circuit breaker the cable being 4 mm PVC
copper or 25 mm2 mineral insulated (mi)
2 The number of socket outlets is unlimited for a floor area up to 20 m 2 with any type of circuit
protection of 20 A using 25 mm2 PVC copper cable or 15 mm2 mi
3 The total number of fused spurs is unlimited
b ring final circuits
These circuits are the same as radial circuits except that the final socket outlet is wired back to the
supply position In effect any outlet is supplied from two directions (Fig 152)
Points to note
1 Every twin-socket outlet counts as two single-socket outlets
2 The number of non-fused spurs must not exceed the total number of points on the ring Fig 158
shows seven points on the ring and five spurs
3 The fuse rating of a fused spur box must not exceed 13 A and the current rating of all points supplied
by the fused spur must not exceed 13 A
4 Non-fused spurs must supply no more than one single or one double socket on the ring Fig 158
shows seven points on the ring and five spurs rating of all points supplied by the fused spur must not
exceed 13 A or one stationary appliance
CapacityMain conductor size
copper (mm2)
Earth conductor
size (mm2)
Circuit breaker
capacity (A)
Up to 600 W 15 15 6
600ndash1200 W 1525 15 10
1200ndash1800 W 254 25 16
41 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Ring circuit
(floor area 100 m2)25 15 3032
A2 radial circuit
(floor area 75 m2)40 25 3032
A3 radial circuit
(floor area 50 m2)25 15 20
Air conditioner (15 tonne) 60 60 3032
Cooker 60 60 3032
Water heater 40 40 20
Objectives
1 Identify component and the specification
2 Wire component according to the schematic diagram
3 Test the functionality of the circuit
42 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board Perforated 1
2 Cut out fuse and neutral link 60A 240V 1each
3 kWh meter 240V 40A 1
4 Switched Socket outlet 13A 240Vac 4
5 Single pole two way switch cw switch
box
5A 240Vac 2
6 RCCB ELCB 63 A Tripping current 100mA
415 Vac
1
7 3 pin plug 240Vac 13A 4
8 Single pole MCB 20 A 2
9 Single pole MCB 6A 1
10 Single pole MCB 20A 2
11 DOL starter 240Vac 2
12 1 phase induction motor 2hp 240 Vac 1
13 Self tapping Wood screw As required
14 DIN rail Stainless steel allum35 mm As required
15 PVC pipe 20mm dia As required
16 End box 20 mm dia 4
17 Flexible wires 05 mm 2 As required
18 Connectors 5 A As required
Procedures
43 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
4 Test the functionality of completed project
LESSON 6 ndash WIRING SYSTEM OF 3 Oslash DISTRIBUTION BOARD
Introduction
44 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
45 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
46 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
47 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
48 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify each component and the specification
2 Wire component according to the schematic diagram given
3 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting Board 450 x 600 mm Perforated metal 1
2 5 pin round socket and plug 415V ac 32A 1
3 Cut out fuse 60 A 3
4 Neutral link 1
5 kWatt hour meter 415V 60A 1
6 ELCB RCCB 3P+N In=63A415 Vac I trip= 300mA 1
7 ELCB RCCB 3P+N In=63A415 Vac I trip= 30mA 1
8 Single pole MCB 6A 240 V 3
9 Single pole MCB 20A 240 V 3
10 DOL starter 20 A 240Vac 2
11 Socket outlet 15 A 240 Vac 1
12 Switched Socket outlet 13 A 240 Vac 3
13 Led indicating light 5A 240 Vac 3
14 Single pole 4 gang 1 way switch 5A 240 Vac 2
15 Single pole 2 way switch 5A 240 Vac 2
16 1 phase induction motor 1 kW 240Vac 1
17 Metal trunking 30 mm x30 mm As required
18 Self tapping Wood screw 4 mm x 20 mm As required
19 DIN rail 25 mm x 1mm
20 GI steel rigid conduit 20mm As required
21 Flexible conduit 20mm As required
22 End box 20 mm 4
23 Flexible wires 05 mm 2 As required
24 Single core PVC insulated wire 15 mm 2 As required
25 Single core PVC insulated wires 25 mm 2 As required
26 Terminal block 10 A As required
Procedures
49 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify each components and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
4 Test the functionality of completed project
1 dead circuit test
2 life circuit
Note Proper earthing should be made
50 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 7 ndash WIRING SYSTEM OF THREE PHASE LIGHTING AND POWER CIRCUIT
51 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
52 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify component and the specification
2 Wire component according to the schematic diagram
3 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting bay Board Perforated metal 180 cm x 180 cm 1
2 k Watt hour meter 415V 60A 1
3 MCCB 415V 60A
4 ELCB RCCB In=60A415 Vac I trip=30mA 1
5 5 pin round Socket and
plug
415Vac 32A 4
6 Single pole MCB 6A 1
7 Triple pole MCB 20A 2
8 Triple pole Main switch 60A 1
9 DOL starter 240Vac 2
10 3 phase induction motor 2hp 415 Vac 1
11 1 phase induction motor 1
12 Metal trunking 30 mm x30 mm As required
13 Self tapping Wood screw 4 mm x 20 mm As required
14 DIN rail 25 mm x 1mm
15 GI steel rigid conduit 20mm As required
16 Flexible conduit 20mm As required
17 End box 20 mm 4
18 Flexible wires 05 mm As required
19 Connectors 10 A As required
Procedures
1 Identify each components and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
4 Test the functionality of completed project
1 dead circuit 2 life circuit test
5 Record the current drawn by the load as connected in star and delta
Note Proper earthing should be made
53 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 8 INSPECTION AND TESTING OF ELECTRICAL INSTALLATION
On completion of a wiring installation a number of tests on the installation have to be conducted to
ascertain that the wiring circuits and connected appliances are safe for use Prior to carrying out the
tests an inspection has to be done The results of the inspectionsupervision and test have to be
presented in Form G (as in Appendix IV) and Form H (as in Appendix V)
To have the test certification as in Form H the following tests shall be conducted
i Continuity Test
ii Insulation Resistance Test
iii Polarity Test
iv Earth Electrode Resistance test and
v Residual Current Device Test
1 Continuity Test
There are 3 main types of continuity tests for the final circuits-
i Protection Conductor Continuity Test
ii Final Ring Circuit Conductor Continuity Test
iii Live and Neutral Conductor Continuity Test
a) Protection Conductor Continuity Test
bull To ascertain that all protection conductors are connected in the correct and effective manner
bull Test equipment ndash Multimeter (Ohm range) or Ohm meter
54 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
bull Test Method
1 1048766 Ensure that the main switch RCD and MCB are open circuited (switched off) and all loads
are disconnected
2 1048766 Connected the test leads as in the Figure 81 The meter reading shall be less than 1 Ω
55 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Final Ring Circuit Conductor Continuity Test
bull To ensure that all conductors around the ring circuit have continuity
bull Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
bull Test Method
1 1048766 Disconnect both the supply source live conductors from the MCB the neutral conductor
from the neutral terminals and the earth conductor from the earth terminal in the distribution
fuse box
2 1048766 Connect the test leads as in the Figure 82 (EE)
3 1048766 Repeat the procedure for (L-L) and (N-N)
4 1048766 The meter reading value shall be less than 1 ohm
56 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Live and Neutral Conductor Continuity Test
a To ensure that each conductor in the circuit has continuity
b Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
2 Test Method
1 1048766 Switch off the Main switch RCD and MCB
2 1048766 Disconnect all loads
3 1048766 Switch on all switches in the circuit
4 1048766 Disconnect the fusesfinal circuit breakers and close the circuit
5 1048766 Carry out the test as shown in Figure 83
6 1048766 The meter reading value shall be less than 1Ω
57 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
58 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
CONTINUITY TEST
Insulation Resistance Test
i Ensure that there is no leakage current between phase conductors phase and neutral conductors and
phase conductor and earth
ii Test the strength of the cable insulation
iii Test Equipment ndash Insulation Resistance Tester operating voltage is 250VDC or 500VDC
iv Test Method
1 1048766 Switch off main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
59 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
4 1048766 Carry out test as in the Table below
5 1048766 Meter reading value shall be less than 1 Megaohm
60 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
61 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Insulation resitance test
62 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
INSULATION RESISTANCE TEST BETWEEN CONDUCTORS AND OPPOSITE POLARITY
Polarity Testi Ensure that each fuse or single pole control and protection device is connected only in the phase
conductor
ii Intermediate contact of Edison screw lamp holder is connected to the phase conductor
iii Ensure that phase neutral and earth conductors at socket outlets are connected at the correct
terminals
iv Test Equipment ndash Multimeter (Ohm range) or Ohm meter
v Test Method
1 1048766 Switch off Main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in Figure 85
63 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
5 1048766 Test switches and single phase control devices at the phase conductors
6 1048766 Test socket outlet connection sources
7 1048766 Test Edison screw lamp holder connections
8 1048766 Meter reading value shall be less than 1 Ω
64 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Polarity test
65 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Earth Electrode Resistance Testi To test the earth electrode resistance
ii To ascertain the suitability of the location of the electrode
iii To ensure that the electrode is not buried within the resistance area of another electrode
iv Test equipment ndash Earth Resistance Tester
v Test method -
1 1048766 Terminal rsquoErsquo is connected to the electrode to be tested (green conductor)
2 1048766 Terminal lsquoPrsquo is connected to the potential spike (yellow conductor) at a distance of 10
meters from the earth electrode
3 1048766 Terminal lsquoCrsquo is connected to the current spike (red conductor) at a distance of 20 meters
from the earth electrode
Earth Electrode Resistance Measurement Method (Figure 86)
This test must be repeated at least three times to ensure that the reading is not affected by interacting
earthing regions
i Record the first reading (Z1) Example Z1 = 10 Ω
ii Move the voltage spike to a distance of 6 meters from the original position Record the second
reading (Z2 ) Example Z2 = 10 Ω
iii Move the voltage spike to a distance of 6 meters from the original position Record the third
reading (Z3) Example Z3 = 10 Ω
66 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Residual Current Device Testi Ensure that the residual current device (RCD) trips within the set time on the occurrence of current
leakage to earth
ii Test Equipment ndash RCD Tester RCCB Tester
iii Test Method 1
1 1048766 Use the Trip Test Button
2 1048766 Press the trip button found on the RCD to determine if it trips or otherwise This test would
not be able to determine the sensitivity of the RCD nor the time taken for it to trip
iv Test Method 2
i 1048766 Use a RCD Tester
ii This equipment is equipped with a 13A plug which can be connected to a 13A socket outlet
Select the RCD sensitivity to be the same as the sensitivity of the RCD to be tested to
determine if the RCD can trip The time to trip shall not exceed 40 mS
iii 1048766 Test method ndash
a) Position the selection switch in accordance with the sensitivity of the RCD used
Example 100 mA 01 A
b) Position the operations switch to lsquoNo Triprsquo (frac12 Rated mA = 50) connect the 3 pin plug to
the 13A socket outlet
67 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
c) Switch on the 13A socket outlet ndash ensure that the P-N and P-E lights light up
This shows that the polarity is correct (Note if both the lights as above do not light up the test cannot
be continued)
d) Press the test button ndash the reading shows less than 200 mS and simultaneously the lsquotestrsquo light lights
up and the P-N and P-E lights do not light up At that instant the RCD will not trip
e) Move the selection switch to 180o (+ve wave) ndash repeat steps (d) and (e) Move the operations
switch to lsquoTriprsquo (Rated mA = 100)
g) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200mS
h) Move the selection switch to 0o (-ve wave)
i) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
j) The above test is repeated until a near correct reading is obtained
k) Record the test results
l) Change the operations switch to lsquoFast Triprsquo and press the test button ndash RCD will trip within a
time not exceeding 40 millisecond
m) Repeat a number of times at 0o or 180o
On completion of a wiring installation a number of tests on the installation have to be conducted to
ascertain that the wiring circuits and connected appliances are safe for use Prior to carrying out the
tests an inspection has to be done the following tests shall be conducted
i Continuity Test
ii Insulation Resistance Test
iii Polarity Test
iv Earth Electrode Resistance test and
v Residual Current Device Test
821 Continuity Test
There are 3 main types of continuity tests for the final circuits-
i Protection Conductor Continuity Test
ii Final Ring Circuit Conductor Continuity Test
68 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
iii Live and Neutral Conductor Continuity Test
a) Protection Conductor Continuity Test
bull To ascertain that all protection conductors are connected in the correct and effective manner
bull Test equipment ndash Multimeter (Ohm range) or Ohm meter
bull Test Method
1 1048766 Ensure that the main switch RCD and MCB are open circuited (switched off) and all loads are
disconnected
2 1048766 Connected the test leads as in the Figure 81
3 1048766 The meter reading shall be less than 1 Ω
Final Ring Circuit Conductor Continuity Test
bull To ensure that all conductors around the ring circuit have continuity
bull Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
bull Test Method
1 1048766 Disconnect both the supply source live conductors from the MCB the neutral conductor
from the neutral terminals and the earth conductor from the earth terminal in the distribution
fuse box
2 1048766 Connect the test leads as in the Figure 82 (EE)
3 1048766 Repeat the procedure for (L-L) and (N-N)
4 1048766 The meter reading value shall be less than 1 ohm Figure 82 - Final Ring Circuit Conductor
Continuity Test Ohm Meter
Disconnect both the supply source cables from mcbfuse
Take readings at earth conductors of both sources and note resistance readings
Live and Neutral Conductor Continuity Test
1 To ensure that each conductor in the circuit has continuity
2 Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
3 Test Method
1 1048766 Switch off the Main switch RCD and MCB
2 1048766 Disconnect all loads
3 1048766 Switch on all switches in the circuit
4 1048766 Disconnect the fusesfinal circuit breakers and close the circuit
5 1048766 Carry out the test as shown in Figure 83
6 1048766 The meter reading value shall be less than 1 ohm Figure 83 - Live and Neutral
Conductor Continuity Test Ohm Meter
Insulation Resistance Test
69 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
i Ensure that there is no leakage current between phase conductors phase and neutral conductors and
phase conductor and earth
ii Test the strength of the cable insulation
iii Test Equipment ndash Insulation Resistance Tester Operating voltage is 250VDC or 500VDC
iv Test Method
1 1048766 Switch off main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in the Table below
5 1048766 Meter reading value shall be less than 1 Megaohm
Polarity Test
i Ensure that each fuse or single pole control and protection device is connected only in the phase
conductor
ii Intermediate contact of Edison screw lamp holder is connected to the phase conductor
iii Ensure that phase neutral and earth conductors at socket outlets are connected at the correct
terminals
iv Test Equipment ndash Multimeter (Ohm range) or Ohm meter
v Test Method
1 1048766 Switch off Main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in Figure 85
5 1048766 Test switches and single phase control devices at the phase conductors
6 1048766 Test socket outlet connection sources
7 1048766 Test Edison screw lamp holder connections
8 1048766 Meter reading value shall be less than 1 Ω
Earth Electrode Resistance Test
i To test the earth electrode resistance
70 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
ii To ascertain the suitability of the location of the electrode
iii To ensure that the electrode is not buried within the resistance area of another electrode
iv Test equipment ndash Earth Resistance Tester
v Test method -
1 1048766 Terminal rsquoErsquo is connected to the electrode to be tested (green conductor)
2 1048766 Terminal lsquoPrsquo is connected to the potential spike (yellow conductor) at a distance of 10
meters from the earth electrode
3 1048766 Terminal lsquoCrsquo is connected to the current spike (red conductor) at a distance of 20 meters
from the earth electrode E P C Electrode 10 meter 10 meter
Figure 86 ndash Earth Electrode Resistance Measurement Test Equipment
Earth Electrode Resistance Measurement Method (Figure 86)
This test must be repeated at least three times to ensure that the reading is not affected by interacting
earthing regions
i Record the first reading (Z1) Example Z1 = 10 Ω
ii Move the voltage spike to a distance of 6 meters from the original position Record the second
reading (Z2) Example Z2 = 10 Ω
iii Move the voltage spike to a distance of 6 meters from the original position Record the third
reading (Z3)
Example Z3 = 10 Ω
Residual Current Device Test
71 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
i Ensure that the residual current device (RCD) trips within the set time on the occurrence of current
leakage to earth
ii Test Equipment ndash RCD Tester RCCB Tester
iii Test Method 1
1 1048766 Use the Trip Test Button
2 1048766 Press the trip button found on the RCD to determine if it trips or otherwise This test would
not be able to determine the sensitivity of the RCD nor the time taken for it to trip
iv Test Method 2
1048766 Use a RCD Tester
This equipment is equipped with a 13A plug which can be connected to a 13A socket outlet Select the
RCD sensitivity to be the same as the sensitivity of the RCD to be tested to determine if the RCD can
trip The time to trip shall not exceed 40 mS
1048766 Test method ndash
a) Position the selection switch in accordance with the sensitivity of the RCD used
Example 100 mA 01 A
b) Position the operations switch to lsquoNo Triprsquo (frac12 Rated mA = 50) connect the 3 pin plug to
the 13A socket outlet
c) Switch on the 13A socket outlet ndash ensure that the P-N and P-E lights light up This shows that
the polarity is correct (Note if both the lights as above do not light up the test cannot be
continued)
d) Press the test button ndash the reading shows less than 200 millisecond and simultaneously the
lsquotestrsquo light lights up and the P-N and P-E lights do not light up At that instant the RCD will
not trip
e) Move the selection switch to 180o (+ve wave) ndash repeat steps (d) and (e) = 100)
f) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
g) Move the selection switch to 0o (-ve wave)
h) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
i) The above test is repeated until a near correct reading is obtained
j) Record the test results
k) Change the operations switch to lsquoFast Triprsquo and press the test button ndash RCD will trip within a
time not exceeding 40 mS
l) Repeat a number of times at 0o or 180o
72 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 9 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (DC)
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
73 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Start stop button 240Vac 5A 2
9 Filament lamp (Bulb ) 240Vac 40W 3
10 Overload Relay 415V 20A 3
11 Three phase induction motor 5 hp 3
12 Single phase step down transformer 2500VA 1
13 Single core PVC insulated Cable 1mm 2 As required
14 Single core PVC insulated Cable 25mm 2 As required
15 DIN rail 35 mm As required
16 PVC type Cable tray 50 mm x 50 mm As required
17 Cable ties 4 ldquo As required
18 Flexible wires 05 mm As required
19 PVC Connectors 5 A amp 20 A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the schematic
diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a optional exercise
i Simple DOL starter
ii Forward reverse DOL starter
iii Forward Reverse Dahlander motor
iv Three motors operated in sequence by DOL starter operated by manual push
button or time delay relay
74 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
a One loop per-cycle
b Continuous operation in a loop
c optional circuit design to represent the same task
v Only one out of three motors to be operated at a time (quiz)
4 Test the functionality of completed project
LESSON 10 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (AC)
75 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 1
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Lamp point 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
76 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
11 Overload Relay 415V 20A 3
12 Three phase induction
motor
5 hp 3
13 Single core PVC insulated
Cable
1mm 2 As required
14 Single core PVC insulated
Cable
25mm 2 As required
15 DIN rail 35 mm As required
16 PVC type Cable tray 50 mm x 50 mm As required
17 Cable ties 4 ldquo As required
18 Flexible wires 05 mm As required
19 PVC Connectors 5 A amp 20 A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the
schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram optional exercise
4 Simple DOL starter
5 Forward reverse DOL starter
6 Test the functionality of completed project
77 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 1
78 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
cm
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Indicating light 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
11 Overload Relay 415V 20A 3
12 Three phase induction motor 5 hp 3
13 Single phase step down
transformer
2500VA 1
14 Single core PVC insulated
Cable
1mm 2 As required
15 Single core PVC insulated
Cable
25mm 2 As required
16 DIN rail 35 mm As required
17 PVC type Cable tray 50 mm x 50 mm As required
18 Cable ties 4 ldquo As required
19 Flexible wires 05 mm As required
20 PVC Connectors 5 A amp 20 A 240 V As required
21 Single pole MCB 6A 240 V 1
22 Single pole MCB 2A 240 V 1
23 Triple pole MCB 20A 415 V 1
24 Mounting board 30 cm x 40 cm x 3
cm
1
25 Relay cw 11 pin socket 10 A 240 Vac 2
26 Time delay relay 10 A 240 Vac 3
27 Triple pole Contactor 20A 240Vac 3
28 Batten type Lamp holder 240Vac 10 A 3
29 Start stop button 240Vac 10A 2
30 Indicating light (Bulb ) 240Vac 25W 3
31 Overload Relay 415V 20A 1
32 Three phase dahlander type
induction motor
5 hp 1
33 Single phase step down
transformer
24024Vac
2500VA
1
79 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
34 Single core PVC insulated
Cable
1mm 2 As required
35 Single core PVC insulated
Cable
25mm 2 As required
36 DIN rail 35 mm As required
37 PVC type Cable tray 50 mm x 50 mm As required
38 Cable ties 4 ldquo As required
39 Flexible wires 075 mm As required
40 PVC Connectors 5 A amp 20 A 240 V As required
41 Terminal block 20A 240Vac As required
Procedures
5 Identify each component according to specification and quantity required from the schematic
diagram attached
6 Test the functionality of each component by using multi-meter or power supply whichever
applicable
7 Wire component according to circuit diagram
8 Three motors operated in sequence by DOL starter operated by manual push button or time
delay relay
a One loop per-cycle
b Continuous operation in a loop
c optional circuit design to represent the same task
d Only one out of three motors to be operated at a time (quiz)
9 Test the functionality of completed project
80 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
BASIC DESIGN INDUSTRIAL MOTOR CONTROL (SEQUENCE CONTROL)
THREE PHASE INDUCTION MOTOR OPERATED IN SEQUENCE BY DIRECT ON LINE
STARTER
LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
81 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
82 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Lcd lamp indicator 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
11 Overload Relay 415V 20A 3
12 Three phase induction motor 5 hp 3
13 Single phase step down transformer 2500VA 1
14 Single core PVC insulated Cable 1mm 2 As required
15 Single core PVC insulated Cable 25mm 2 As required
16 DIN rail 35 mm As required
17 PVC type Cable tray 50 mm x 50 mm As required
18 Cable ties 4 ldquo As required
19 Flexible wires 1 mm Oslash As required
20 PVC Terminal block 10A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the schematic
diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a optional exercise
i Forward Reverse dahlander motor
4 Test the functionality of completed project
83 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
THREE PHASE DAHLANDER TYPE INDUCTION MOTOR OPERATED FORWARD AND
REVERSE OPERATION BY DIRECT ON LINE STARTER
84 ndash 99EASYTECH ENTERPRISE
LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
Introduction
If a motors windings are connected in the star configuration any two phases will be in series across
the supply and hence the line current will be smaller(by 577) than if the windings were connected in
the delta arrangement
Hence larger-type motors with heavy starting currents are first connected in star and then when the
starting currents fall in delta This of course means that all six of the ends of the windings must be
brought to terminations outside the casing (Fig 833)
EZTECH
EZTECH ELECTRICAL INSTALLATION GUIDE
The automatic version of this starter incorporates a timing relay which automatically changes the
connections from star to delta Figs 834 and 835 show the wiring and schematic diagrams for a star
delta starter
Objectives
1 Identify component and the specification
2 Design forward reverse star delta starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
2 ndash 99EASYTECH ENTERPRISE
REV -C
LEGENDMCCB Moulded Case Circuit BreakerTOR Thermal Over Load RelayFOW-C Mains Forward ContactorREV-C Mains Reverse ContactorDC Delta ContactorSC Star ContactorS-SW Mains Selector Switch
SC
V2
W2
U2
DC
V1
W1
U1
TOR
TOR
FOW-C
30A MCCB
TOR
MAIN CIRCUIT FORWARD REVERSE STAR DELTA
RYBN S
-SW
3 PHASEINDUCTION MOTOR
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Relay 10 A 240V 3
5 Triple pole Contactor
6 cw NO NC auxiliary contact
240Vac 20 A 4
7 Overload Relay 415 V 1
8 LED indicator 240vac 5 A 4
9 Start stop button 240Vac 5A 2
10 DIN rail 35 mm As required
11 Flexible wires 1 mm As required
12 Single core PVC insulated
wire
25 mm As required
13 Terminal block 20 A As required
14 Squirrel cage motor 5kW 1
15 5 pin plug and socket 415V 20A 1
16 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
3 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
a Manual star delta
b Manual Forward reverse star delta starter
c Automatic star delta starter
d Automatic Forward reverse star delta starter
4 Test the functionality of completed project
4 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
Objectives
1 Identify component and the specification
2 Design auto transformer starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
5 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Autotransformer starter is used to start a 3 phase induction motor that has a rating between 10 to 15 hp
6 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Autotransformer set 10Kw 415 V 50 Hz 1
5 Triple pole Contactor 240Vac 4
6 Batten type Lamp holder 240 Vac 105 A 4
7 Start stop button 240Vac 10A 4
8 Filament lamp (Bulb ) 240Vac 40W 4
9 DIN rail 35 mm As required
10 Flexible wires 1 mm As required
7 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
11 Single core PVC insulated
wire
25 mm As required
12 Terminal block 20 A As required
13 Squirrel cage motor 10kW 1
14 5 pin plug and socket 415V 20A 1
15 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a open transient autotransformer starter
b close transient autotransformer starter
c Forward reverse autotransformer starter
4 Test the functionality of completed project
8 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
Objectives
1 Identify component and the specification
2 Design rotor resistance starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
9 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Rotor Resistor set 10kW 1
5 Triple pole Contactor 240Vac 20A 4
6 Indicating light 240vac 5 A 4
7 Start stop push button 240Vac 5A 4
8 DIN rail 35 mm As required
9 Flexible wires 1 mm 2 As required
10 Single core PVC insulated wire 25 mm 2 As required
11 Terminal block 20 A As required
12 Slip Ring motor 10kW 1
13 5 pin round 3 phase socket 415V 20A 1
14 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
10 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
4 Test the functionality of completed project
a Dead circuit test b Life circuit test
5 Measure starting and running Amps
LESSON 16
TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
An installation in general will suffer damage
Damage usually occurs on the electric motor control as follows
1 Damage to the main circuit
2 Damage to the control circuit
The cause of the damage
i Overcurrent overload short circuit
ii Leakage current to ground
iii Equipment malfunction
iv The main control circuit
a Trip of main circuit protection devices fire
b Defect of motor terminal such as short circuit fire loose
v The control circuit is not functioning -
a contactor relay relay time overload relay does not work damaged burned
b Loose cable connection disconnected
Detecting and Repairing Damage
Examples of damage are as follows
i Motor does not work
ii Motor function and overload relay trips
iii Motor function but only partially functional control circuit
Methods of detecting damage
Among the known methods necessary to detect damage are as follows
1 Turn off the electricity at the main switch (main switch) in order to avoid any danger during the
work carried out to detect damage
2 Check all the protective gear that controls the motor control main circuit
11 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
3 Make sure the damage function control circuit
4 Check the control circuit according to the schematic circuit diagram of the motor control
5 Check the operation of the control circuit
Note
Use wiring that has been installed on the SYSTEM OF MOTOR CONTROL BOARD by Forward
Reverse control circuit for Star Delta to test and look for damage
SELF-ASSESSMENT QUESTIONS
1 (a) Explain what is meant by the term lsquoback emfrsquo in a motor
(b) Outline the basic differences between series shunt and compound wound dc motors
2 (a) With the aid of diagrams explain how the speed of series shunt and compound-wound motors
may be controlled
(b) A 440V dc shunt-wound motor has a field resistance of 200R and an armature resistance of 06 R
When its speed is 20 rev d second the current drawn from the supply is 122A Calculate its back
emf at this speed If the speed were decreased to 19 revssecond the field flux remaining unchanged
calculate the new back emf and the new armature current
3 A load of 64 kW at 240 V is supplied from the terminals of a shunt-wound dc generator The field
resistance is 180 A Calculate the armature current
4 (a) Explain with the aid of a diagram how a rotating magnetic field may be
(b) What is meant by lsquosynchronous speedrsquo
Calculate the synchronous obtained speed of a 12 pole motor if the supply frequency is 50Hz
5 (a) Explain the action of a synchronous motor
(b) What methods are available to start a synchronous motor Explain with diagrams
6 (a) Explain the action of a cage induction motor
(b) What is meant by the term lsquosliprsquo
Calculate the percentage slip of a six pole induction motor running at 162 revssecond from a 50 Hz
supply
7 Describe with sketches three different ways of starting a single-phase induction motor
12 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
8 Explain with the aid of a sketch the action of a three-phase DOL starter
What are dashpots used for How are remote start and stop buttons connected
9 A I0 kW 240V 50Hz single-phase cage rotor induction motor is 85efficient and has a PF of 068
lagging Calculate the motor current and the value of capacitor required to raise the PF to 093
lagging
10 Calculate the torque developed by an 18 kW four-pole induction motor run at 35 slip from a
50Hz supply
APPENDIX 1
13 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 11
14 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 111
Attachment Reference
httpswwwtlc-directcoukBook621htm
httpwwwstgovmyindexphpms
15 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
29 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
30 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
31 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 2 WIRING SYSTEM OF SINGLE PHASE LIGHTING CIRCUIT Introduction
Objectives
1 Identify component and the specification
2 Wire component according to the schematic diagram
3 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Wiring bay Perforated metal 180 cm x 180 cm 1
2 Cut out fuse 63 A 240 V 1
3 Neutral link 1
4 Single pole one way switch cw
switch box
5A 240Vac 4
5 single pole two way switch cw
switch box
5A 240Vac 2
6 RCCB In = 40 A Tripping current
100mA240 Vac 50 Hz
1
7 Main switch 32 A 240V 1
8 kWatthour meter 40 A 240 Vac 1
9 Single pole MCB 6A 240 Vac 1
10 Self tapping Wood screw As required
11 DIN rail 35 mm width As required
32 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
12 PVC trunking 50 mm x 50 mm As required
13 Terminal blocks 5 A As required
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
1 One way switch to control one lamp
2 One way switch to control two lamps
3 Two of two way switch to control one lamp
4 Two of single pole two way switch and one of an intermediate switch to control one
lamp
5 One unit of ceiling fan and fan regulator to be controlled by one way switch
4 Test the functionality of completed project
LESSON 3ndash WIRING SYSTEM OF SINGLE PHASE POWER CIRCUIT Introduction
33 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
34 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify types of component and its specification
2 Wire component according to the schematic diagram given
3 Test the functionality of the circuit dead circuit test life circuit test
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board Perforated Metal 1
2 kWh meter 240 V 40 A 1
3 Socket outlet 13A 240Vac 4
4 RCCB 40A Trip Amps
30mA240 Vac
1
5 3 pin socket 240Vac 13A 4
6 Single pole MCB 20A 240 V 2
7 DOL starter 1 kW 240Vac 2
8 1 phase induction motor 2Hp 240 Vac 1
9 Cooker control unit 4kW 240Vac 1
10 Water heater point 4kW 240 Vac 1
11 DIN rail 35 mm As required
12 PVC casing 20mm As required
13 Flexible wires 05 mm As required
14 Terminal block 10 A As required
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Wire two unit of 13 A socket outlet in radial circuit
3 Wire four units of 13 A socket outlet in ring circuit
4 Wire one unit DOL starter for air-conditioner point
5 Wire one unit of cooker control unit point
6 Wire one unit of water heater point
7 Test the functionality of each component by using mmeter or power supply whichever
applicable
8 Wire component according to circuit diagram
9 Test the functionality of completed project dead circuit test life circuit test
Note
35 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Ensure that the correct rating of protection device and size of wire used
LESSON 4ndash CONDUIT BENDING AND TRUNKING FABRICATION TECHNIQUE
Common fitting used in an industrial wiring
Cutting and threading the condute
36 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
37 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
38 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify conduit fitting and the specification
2 Measure and Cut steel conduit according to specified dimension
3 Bend and fabricate conduit at 45 90 according to layout diagram
4 Wire component according to the schematic diagram
5 Test the functionality of the circuit
39 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Conduit Bender Oslash 19 mm ( frac34 ldquo) 1
2 Measuring Tape 3 metre 1
3 Hacksaw frame and blade 30cm 1
4 Conduit cutter 1
5 Pipe Vise 1
6 Pipe Wrench 1
7 Ratchet Dies 20 mm 1
8 Metal trunking 50 mm x 50 mm 1
9 GI conduit 20mm 1
10 End box 20 mm 1
11 Flexible wires 05 mm As required
12 Connectors 5 A As required
13 Single core PVC ins Cable 25 mm 2 As required
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Wire two unit of 13 A socket outlet in radial circuit
3 Wire four unit of 13 A socket outlet in ring circuit
4 Wire one unit DOL starter for air-conditioner point
5 Wire one unit of cooker control unit point
6 Wire one unit of water heater point
7 Test the functionality of each component by using multimeter or power supply whichever
applicable
8 Wire component according to circuit diagram
9 Test the functionality of completed project
Note
Ensure that the rating of protection device and size of wire
K prior to 31 March
2004 (BS 7671)
(formerly)
bare conductor
sleeved at terminations (formerly)
40 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 5 ndashWIRING SYSTEM OF 1 Oslash LIGHTING AND POWER CIRCUIT
POWER CIRCUITSa Radial circuits
Radial circuits are arranged in the same way as item 1 above in lighting layouts in that each socket
outlet is supplied via the previous one
Points to note
1 The number of socket outlets complying with BS 1363 is unlimited for a floor area of up to 50m 2 if
the circuit protection is a 30 A or 32 A cartridge fuse or circuit breaker the cable being 4 mm PVC
copper or 25 mm2 mineral insulated (mi)
2 The number of socket outlets is unlimited for a floor area up to 20 m 2 with any type of circuit
protection of 20 A using 25 mm2 PVC copper cable or 15 mm2 mi
3 The total number of fused spurs is unlimited
b ring final circuits
These circuits are the same as radial circuits except that the final socket outlet is wired back to the
supply position In effect any outlet is supplied from two directions (Fig 152)
Points to note
1 Every twin-socket outlet counts as two single-socket outlets
2 The number of non-fused spurs must not exceed the total number of points on the ring Fig 158
shows seven points on the ring and five spurs
3 The fuse rating of a fused spur box must not exceed 13 A and the current rating of all points supplied
by the fused spur must not exceed 13 A
4 Non-fused spurs must supply no more than one single or one double socket on the ring Fig 158
shows seven points on the ring and five spurs rating of all points supplied by the fused spur must not
exceed 13 A or one stationary appliance
CapacityMain conductor size
copper (mm2)
Earth conductor
size (mm2)
Circuit breaker
capacity (A)
Up to 600 W 15 15 6
600ndash1200 W 1525 15 10
1200ndash1800 W 254 25 16
41 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Ring circuit
(floor area 100 m2)25 15 3032
A2 radial circuit
(floor area 75 m2)40 25 3032
A3 radial circuit
(floor area 50 m2)25 15 20
Air conditioner (15 tonne) 60 60 3032
Cooker 60 60 3032
Water heater 40 40 20
Objectives
1 Identify component and the specification
2 Wire component according to the schematic diagram
3 Test the functionality of the circuit
42 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board Perforated 1
2 Cut out fuse and neutral link 60A 240V 1each
3 kWh meter 240V 40A 1
4 Switched Socket outlet 13A 240Vac 4
5 Single pole two way switch cw switch
box
5A 240Vac 2
6 RCCB ELCB 63 A Tripping current 100mA
415 Vac
1
7 3 pin plug 240Vac 13A 4
8 Single pole MCB 20 A 2
9 Single pole MCB 6A 1
10 Single pole MCB 20A 2
11 DOL starter 240Vac 2
12 1 phase induction motor 2hp 240 Vac 1
13 Self tapping Wood screw As required
14 DIN rail Stainless steel allum35 mm As required
15 PVC pipe 20mm dia As required
16 End box 20 mm dia 4
17 Flexible wires 05 mm 2 As required
18 Connectors 5 A As required
Procedures
43 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
4 Test the functionality of completed project
LESSON 6 ndash WIRING SYSTEM OF 3 Oslash DISTRIBUTION BOARD
Introduction
44 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
45 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
46 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
47 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
48 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify each component and the specification
2 Wire component according to the schematic diagram given
3 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting Board 450 x 600 mm Perforated metal 1
2 5 pin round socket and plug 415V ac 32A 1
3 Cut out fuse 60 A 3
4 Neutral link 1
5 kWatt hour meter 415V 60A 1
6 ELCB RCCB 3P+N In=63A415 Vac I trip= 300mA 1
7 ELCB RCCB 3P+N In=63A415 Vac I trip= 30mA 1
8 Single pole MCB 6A 240 V 3
9 Single pole MCB 20A 240 V 3
10 DOL starter 20 A 240Vac 2
11 Socket outlet 15 A 240 Vac 1
12 Switched Socket outlet 13 A 240 Vac 3
13 Led indicating light 5A 240 Vac 3
14 Single pole 4 gang 1 way switch 5A 240 Vac 2
15 Single pole 2 way switch 5A 240 Vac 2
16 1 phase induction motor 1 kW 240Vac 1
17 Metal trunking 30 mm x30 mm As required
18 Self tapping Wood screw 4 mm x 20 mm As required
19 DIN rail 25 mm x 1mm
20 GI steel rigid conduit 20mm As required
21 Flexible conduit 20mm As required
22 End box 20 mm 4
23 Flexible wires 05 mm 2 As required
24 Single core PVC insulated wire 15 mm 2 As required
25 Single core PVC insulated wires 25 mm 2 As required
26 Terminal block 10 A As required
Procedures
49 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify each components and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
4 Test the functionality of completed project
1 dead circuit test
2 life circuit
Note Proper earthing should be made
50 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 7 ndash WIRING SYSTEM OF THREE PHASE LIGHTING AND POWER CIRCUIT
51 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
52 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify component and the specification
2 Wire component according to the schematic diagram
3 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting bay Board Perforated metal 180 cm x 180 cm 1
2 k Watt hour meter 415V 60A 1
3 MCCB 415V 60A
4 ELCB RCCB In=60A415 Vac I trip=30mA 1
5 5 pin round Socket and
plug
415Vac 32A 4
6 Single pole MCB 6A 1
7 Triple pole MCB 20A 2
8 Triple pole Main switch 60A 1
9 DOL starter 240Vac 2
10 3 phase induction motor 2hp 415 Vac 1
11 1 phase induction motor 1
12 Metal trunking 30 mm x30 mm As required
13 Self tapping Wood screw 4 mm x 20 mm As required
14 DIN rail 25 mm x 1mm
15 GI steel rigid conduit 20mm As required
16 Flexible conduit 20mm As required
17 End box 20 mm 4
18 Flexible wires 05 mm As required
19 Connectors 10 A As required
Procedures
1 Identify each components and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
4 Test the functionality of completed project
1 dead circuit 2 life circuit test
5 Record the current drawn by the load as connected in star and delta
Note Proper earthing should be made
53 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 8 INSPECTION AND TESTING OF ELECTRICAL INSTALLATION
On completion of a wiring installation a number of tests on the installation have to be conducted to
ascertain that the wiring circuits and connected appliances are safe for use Prior to carrying out the
tests an inspection has to be done The results of the inspectionsupervision and test have to be
presented in Form G (as in Appendix IV) and Form H (as in Appendix V)
To have the test certification as in Form H the following tests shall be conducted
i Continuity Test
ii Insulation Resistance Test
iii Polarity Test
iv Earth Electrode Resistance test and
v Residual Current Device Test
1 Continuity Test
There are 3 main types of continuity tests for the final circuits-
i Protection Conductor Continuity Test
ii Final Ring Circuit Conductor Continuity Test
iii Live and Neutral Conductor Continuity Test
a) Protection Conductor Continuity Test
bull To ascertain that all protection conductors are connected in the correct and effective manner
bull Test equipment ndash Multimeter (Ohm range) or Ohm meter
54 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
bull Test Method
1 1048766 Ensure that the main switch RCD and MCB are open circuited (switched off) and all loads
are disconnected
2 1048766 Connected the test leads as in the Figure 81 The meter reading shall be less than 1 Ω
55 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Final Ring Circuit Conductor Continuity Test
bull To ensure that all conductors around the ring circuit have continuity
bull Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
bull Test Method
1 1048766 Disconnect both the supply source live conductors from the MCB the neutral conductor
from the neutral terminals and the earth conductor from the earth terminal in the distribution
fuse box
2 1048766 Connect the test leads as in the Figure 82 (EE)
3 1048766 Repeat the procedure for (L-L) and (N-N)
4 1048766 The meter reading value shall be less than 1 ohm
56 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Live and Neutral Conductor Continuity Test
a To ensure that each conductor in the circuit has continuity
b Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
2 Test Method
1 1048766 Switch off the Main switch RCD and MCB
2 1048766 Disconnect all loads
3 1048766 Switch on all switches in the circuit
4 1048766 Disconnect the fusesfinal circuit breakers and close the circuit
5 1048766 Carry out the test as shown in Figure 83
6 1048766 The meter reading value shall be less than 1Ω
57 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
58 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
CONTINUITY TEST
Insulation Resistance Test
i Ensure that there is no leakage current between phase conductors phase and neutral conductors and
phase conductor and earth
ii Test the strength of the cable insulation
iii Test Equipment ndash Insulation Resistance Tester operating voltage is 250VDC or 500VDC
iv Test Method
1 1048766 Switch off main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
59 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
4 1048766 Carry out test as in the Table below
5 1048766 Meter reading value shall be less than 1 Megaohm
60 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
61 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Insulation resitance test
62 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
INSULATION RESISTANCE TEST BETWEEN CONDUCTORS AND OPPOSITE POLARITY
Polarity Testi Ensure that each fuse or single pole control and protection device is connected only in the phase
conductor
ii Intermediate contact of Edison screw lamp holder is connected to the phase conductor
iii Ensure that phase neutral and earth conductors at socket outlets are connected at the correct
terminals
iv Test Equipment ndash Multimeter (Ohm range) or Ohm meter
v Test Method
1 1048766 Switch off Main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in Figure 85
63 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
5 1048766 Test switches and single phase control devices at the phase conductors
6 1048766 Test socket outlet connection sources
7 1048766 Test Edison screw lamp holder connections
8 1048766 Meter reading value shall be less than 1 Ω
64 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Polarity test
65 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Earth Electrode Resistance Testi To test the earth electrode resistance
ii To ascertain the suitability of the location of the electrode
iii To ensure that the electrode is not buried within the resistance area of another electrode
iv Test equipment ndash Earth Resistance Tester
v Test method -
1 1048766 Terminal rsquoErsquo is connected to the electrode to be tested (green conductor)
2 1048766 Terminal lsquoPrsquo is connected to the potential spike (yellow conductor) at a distance of 10
meters from the earth electrode
3 1048766 Terminal lsquoCrsquo is connected to the current spike (red conductor) at a distance of 20 meters
from the earth electrode
Earth Electrode Resistance Measurement Method (Figure 86)
This test must be repeated at least three times to ensure that the reading is not affected by interacting
earthing regions
i Record the first reading (Z1) Example Z1 = 10 Ω
ii Move the voltage spike to a distance of 6 meters from the original position Record the second
reading (Z2 ) Example Z2 = 10 Ω
iii Move the voltage spike to a distance of 6 meters from the original position Record the third
reading (Z3) Example Z3 = 10 Ω
66 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Residual Current Device Testi Ensure that the residual current device (RCD) trips within the set time on the occurrence of current
leakage to earth
ii Test Equipment ndash RCD Tester RCCB Tester
iii Test Method 1
1 1048766 Use the Trip Test Button
2 1048766 Press the trip button found on the RCD to determine if it trips or otherwise This test would
not be able to determine the sensitivity of the RCD nor the time taken for it to trip
iv Test Method 2
i 1048766 Use a RCD Tester
ii This equipment is equipped with a 13A plug which can be connected to a 13A socket outlet
Select the RCD sensitivity to be the same as the sensitivity of the RCD to be tested to
determine if the RCD can trip The time to trip shall not exceed 40 mS
iii 1048766 Test method ndash
a) Position the selection switch in accordance with the sensitivity of the RCD used
Example 100 mA 01 A
b) Position the operations switch to lsquoNo Triprsquo (frac12 Rated mA = 50) connect the 3 pin plug to
the 13A socket outlet
67 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
c) Switch on the 13A socket outlet ndash ensure that the P-N and P-E lights light up
This shows that the polarity is correct (Note if both the lights as above do not light up the test cannot
be continued)
d) Press the test button ndash the reading shows less than 200 mS and simultaneously the lsquotestrsquo light lights
up and the P-N and P-E lights do not light up At that instant the RCD will not trip
e) Move the selection switch to 180o (+ve wave) ndash repeat steps (d) and (e) Move the operations
switch to lsquoTriprsquo (Rated mA = 100)
g) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200mS
h) Move the selection switch to 0o (-ve wave)
i) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
j) The above test is repeated until a near correct reading is obtained
k) Record the test results
l) Change the operations switch to lsquoFast Triprsquo and press the test button ndash RCD will trip within a
time not exceeding 40 millisecond
m) Repeat a number of times at 0o or 180o
On completion of a wiring installation a number of tests on the installation have to be conducted to
ascertain that the wiring circuits and connected appliances are safe for use Prior to carrying out the
tests an inspection has to be done the following tests shall be conducted
i Continuity Test
ii Insulation Resistance Test
iii Polarity Test
iv Earth Electrode Resistance test and
v Residual Current Device Test
821 Continuity Test
There are 3 main types of continuity tests for the final circuits-
i Protection Conductor Continuity Test
ii Final Ring Circuit Conductor Continuity Test
68 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
iii Live and Neutral Conductor Continuity Test
a) Protection Conductor Continuity Test
bull To ascertain that all protection conductors are connected in the correct and effective manner
bull Test equipment ndash Multimeter (Ohm range) or Ohm meter
bull Test Method
1 1048766 Ensure that the main switch RCD and MCB are open circuited (switched off) and all loads are
disconnected
2 1048766 Connected the test leads as in the Figure 81
3 1048766 The meter reading shall be less than 1 Ω
Final Ring Circuit Conductor Continuity Test
bull To ensure that all conductors around the ring circuit have continuity
bull Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
bull Test Method
1 1048766 Disconnect both the supply source live conductors from the MCB the neutral conductor
from the neutral terminals and the earth conductor from the earth terminal in the distribution
fuse box
2 1048766 Connect the test leads as in the Figure 82 (EE)
3 1048766 Repeat the procedure for (L-L) and (N-N)
4 1048766 The meter reading value shall be less than 1 ohm Figure 82 - Final Ring Circuit Conductor
Continuity Test Ohm Meter
Disconnect both the supply source cables from mcbfuse
Take readings at earth conductors of both sources and note resistance readings
Live and Neutral Conductor Continuity Test
1 To ensure that each conductor in the circuit has continuity
2 Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
3 Test Method
1 1048766 Switch off the Main switch RCD and MCB
2 1048766 Disconnect all loads
3 1048766 Switch on all switches in the circuit
4 1048766 Disconnect the fusesfinal circuit breakers and close the circuit
5 1048766 Carry out the test as shown in Figure 83
6 1048766 The meter reading value shall be less than 1 ohm Figure 83 - Live and Neutral
Conductor Continuity Test Ohm Meter
Insulation Resistance Test
69 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
i Ensure that there is no leakage current between phase conductors phase and neutral conductors and
phase conductor and earth
ii Test the strength of the cable insulation
iii Test Equipment ndash Insulation Resistance Tester Operating voltage is 250VDC or 500VDC
iv Test Method
1 1048766 Switch off main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in the Table below
5 1048766 Meter reading value shall be less than 1 Megaohm
Polarity Test
i Ensure that each fuse or single pole control and protection device is connected only in the phase
conductor
ii Intermediate contact of Edison screw lamp holder is connected to the phase conductor
iii Ensure that phase neutral and earth conductors at socket outlets are connected at the correct
terminals
iv Test Equipment ndash Multimeter (Ohm range) or Ohm meter
v Test Method
1 1048766 Switch off Main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in Figure 85
5 1048766 Test switches and single phase control devices at the phase conductors
6 1048766 Test socket outlet connection sources
7 1048766 Test Edison screw lamp holder connections
8 1048766 Meter reading value shall be less than 1 Ω
Earth Electrode Resistance Test
i To test the earth electrode resistance
70 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
ii To ascertain the suitability of the location of the electrode
iii To ensure that the electrode is not buried within the resistance area of another electrode
iv Test equipment ndash Earth Resistance Tester
v Test method -
1 1048766 Terminal rsquoErsquo is connected to the electrode to be tested (green conductor)
2 1048766 Terminal lsquoPrsquo is connected to the potential spike (yellow conductor) at a distance of 10
meters from the earth electrode
3 1048766 Terminal lsquoCrsquo is connected to the current spike (red conductor) at a distance of 20 meters
from the earth electrode E P C Electrode 10 meter 10 meter
Figure 86 ndash Earth Electrode Resistance Measurement Test Equipment
Earth Electrode Resistance Measurement Method (Figure 86)
This test must be repeated at least three times to ensure that the reading is not affected by interacting
earthing regions
i Record the first reading (Z1) Example Z1 = 10 Ω
ii Move the voltage spike to a distance of 6 meters from the original position Record the second
reading (Z2) Example Z2 = 10 Ω
iii Move the voltage spike to a distance of 6 meters from the original position Record the third
reading (Z3)
Example Z3 = 10 Ω
Residual Current Device Test
71 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
i Ensure that the residual current device (RCD) trips within the set time on the occurrence of current
leakage to earth
ii Test Equipment ndash RCD Tester RCCB Tester
iii Test Method 1
1 1048766 Use the Trip Test Button
2 1048766 Press the trip button found on the RCD to determine if it trips or otherwise This test would
not be able to determine the sensitivity of the RCD nor the time taken for it to trip
iv Test Method 2
1048766 Use a RCD Tester
This equipment is equipped with a 13A plug which can be connected to a 13A socket outlet Select the
RCD sensitivity to be the same as the sensitivity of the RCD to be tested to determine if the RCD can
trip The time to trip shall not exceed 40 mS
1048766 Test method ndash
a) Position the selection switch in accordance with the sensitivity of the RCD used
Example 100 mA 01 A
b) Position the operations switch to lsquoNo Triprsquo (frac12 Rated mA = 50) connect the 3 pin plug to
the 13A socket outlet
c) Switch on the 13A socket outlet ndash ensure that the P-N and P-E lights light up This shows that
the polarity is correct (Note if both the lights as above do not light up the test cannot be
continued)
d) Press the test button ndash the reading shows less than 200 millisecond and simultaneously the
lsquotestrsquo light lights up and the P-N and P-E lights do not light up At that instant the RCD will
not trip
e) Move the selection switch to 180o (+ve wave) ndash repeat steps (d) and (e) = 100)
f) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
g) Move the selection switch to 0o (-ve wave)
h) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
i) The above test is repeated until a near correct reading is obtained
j) Record the test results
k) Change the operations switch to lsquoFast Triprsquo and press the test button ndash RCD will trip within a
time not exceeding 40 mS
l) Repeat a number of times at 0o or 180o
72 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 9 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (DC)
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
73 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Start stop button 240Vac 5A 2
9 Filament lamp (Bulb ) 240Vac 40W 3
10 Overload Relay 415V 20A 3
11 Three phase induction motor 5 hp 3
12 Single phase step down transformer 2500VA 1
13 Single core PVC insulated Cable 1mm 2 As required
14 Single core PVC insulated Cable 25mm 2 As required
15 DIN rail 35 mm As required
16 PVC type Cable tray 50 mm x 50 mm As required
17 Cable ties 4 ldquo As required
18 Flexible wires 05 mm As required
19 PVC Connectors 5 A amp 20 A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the schematic
diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a optional exercise
i Simple DOL starter
ii Forward reverse DOL starter
iii Forward Reverse Dahlander motor
iv Three motors operated in sequence by DOL starter operated by manual push
button or time delay relay
74 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
a One loop per-cycle
b Continuous operation in a loop
c optional circuit design to represent the same task
v Only one out of three motors to be operated at a time (quiz)
4 Test the functionality of completed project
LESSON 10 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (AC)
75 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 1
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Lamp point 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
76 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
11 Overload Relay 415V 20A 3
12 Three phase induction
motor
5 hp 3
13 Single core PVC insulated
Cable
1mm 2 As required
14 Single core PVC insulated
Cable
25mm 2 As required
15 DIN rail 35 mm As required
16 PVC type Cable tray 50 mm x 50 mm As required
17 Cable ties 4 ldquo As required
18 Flexible wires 05 mm As required
19 PVC Connectors 5 A amp 20 A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the
schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram optional exercise
4 Simple DOL starter
5 Forward reverse DOL starter
6 Test the functionality of completed project
77 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 1
78 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
cm
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Indicating light 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
11 Overload Relay 415V 20A 3
12 Three phase induction motor 5 hp 3
13 Single phase step down
transformer
2500VA 1
14 Single core PVC insulated
Cable
1mm 2 As required
15 Single core PVC insulated
Cable
25mm 2 As required
16 DIN rail 35 mm As required
17 PVC type Cable tray 50 mm x 50 mm As required
18 Cable ties 4 ldquo As required
19 Flexible wires 05 mm As required
20 PVC Connectors 5 A amp 20 A 240 V As required
21 Single pole MCB 6A 240 V 1
22 Single pole MCB 2A 240 V 1
23 Triple pole MCB 20A 415 V 1
24 Mounting board 30 cm x 40 cm x 3
cm
1
25 Relay cw 11 pin socket 10 A 240 Vac 2
26 Time delay relay 10 A 240 Vac 3
27 Triple pole Contactor 20A 240Vac 3
28 Batten type Lamp holder 240Vac 10 A 3
29 Start stop button 240Vac 10A 2
30 Indicating light (Bulb ) 240Vac 25W 3
31 Overload Relay 415V 20A 1
32 Three phase dahlander type
induction motor
5 hp 1
33 Single phase step down
transformer
24024Vac
2500VA
1
79 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
34 Single core PVC insulated
Cable
1mm 2 As required
35 Single core PVC insulated
Cable
25mm 2 As required
36 DIN rail 35 mm As required
37 PVC type Cable tray 50 mm x 50 mm As required
38 Cable ties 4 ldquo As required
39 Flexible wires 075 mm As required
40 PVC Connectors 5 A amp 20 A 240 V As required
41 Terminal block 20A 240Vac As required
Procedures
5 Identify each component according to specification and quantity required from the schematic
diagram attached
6 Test the functionality of each component by using multi-meter or power supply whichever
applicable
7 Wire component according to circuit diagram
8 Three motors operated in sequence by DOL starter operated by manual push button or time
delay relay
a One loop per-cycle
b Continuous operation in a loop
c optional circuit design to represent the same task
d Only one out of three motors to be operated at a time (quiz)
9 Test the functionality of completed project
80 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
BASIC DESIGN INDUSTRIAL MOTOR CONTROL (SEQUENCE CONTROL)
THREE PHASE INDUCTION MOTOR OPERATED IN SEQUENCE BY DIRECT ON LINE
STARTER
LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
81 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
82 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Lcd lamp indicator 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
11 Overload Relay 415V 20A 3
12 Three phase induction motor 5 hp 3
13 Single phase step down transformer 2500VA 1
14 Single core PVC insulated Cable 1mm 2 As required
15 Single core PVC insulated Cable 25mm 2 As required
16 DIN rail 35 mm As required
17 PVC type Cable tray 50 mm x 50 mm As required
18 Cable ties 4 ldquo As required
19 Flexible wires 1 mm Oslash As required
20 PVC Terminal block 10A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the schematic
diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a optional exercise
i Forward Reverse dahlander motor
4 Test the functionality of completed project
83 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
THREE PHASE DAHLANDER TYPE INDUCTION MOTOR OPERATED FORWARD AND
REVERSE OPERATION BY DIRECT ON LINE STARTER
84 ndash 99EASYTECH ENTERPRISE
LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
Introduction
If a motors windings are connected in the star configuration any two phases will be in series across
the supply and hence the line current will be smaller(by 577) than if the windings were connected in
the delta arrangement
Hence larger-type motors with heavy starting currents are first connected in star and then when the
starting currents fall in delta This of course means that all six of the ends of the windings must be
brought to terminations outside the casing (Fig 833)
EZTECH
EZTECH ELECTRICAL INSTALLATION GUIDE
The automatic version of this starter incorporates a timing relay which automatically changes the
connections from star to delta Figs 834 and 835 show the wiring and schematic diagrams for a star
delta starter
Objectives
1 Identify component and the specification
2 Design forward reverse star delta starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
2 ndash 99EASYTECH ENTERPRISE
REV -C
LEGENDMCCB Moulded Case Circuit BreakerTOR Thermal Over Load RelayFOW-C Mains Forward ContactorREV-C Mains Reverse ContactorDC Delta ContactorSC Star ContactorS-SW Mains Selector Switch
SC
V2
W2
U2
DC
V1
W1
U1
TOR
TOR
FOW-C
30A MCCB
TOR
MAIN CIRCUIT FORWARD REVERSE STAR DELTA
RYBN S
-SW
3 PHASEINDUCTION MOTOR
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Relay 10 A 240V 3
5 Triple pole Contactor
6 cw NO NC auxiliary contact
240Vac 20 A 4
7 Overload Relay 415 V 1
8 LED indicator 240vac 5 A 4
9 Start stop button 240Vac 5A 2
10 DIN rail 35 mm As required
11 Flexible wires 1 mm As required
12 Single core PVC insulated
wire
25 mm As required
13 Terminal block 20 A As required
14 Squirrel cage motor 5kW 1
15 5 pin plug and socket 415V 20A 1
16 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
3 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
a Manual star delta
b Manual Forward reverse star delta starter
c Automatic star delta starter
d Automatic Forward reverse star delta starter
4 Test the functionality of completed project
4 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
Objectives
1 Identify component and the specification
2 Design auto transformer starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
5 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Autotransformer starter is used to start a 3 phase induction motor that has a rating between 10 to 15 hp
6 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Autotransformer set 10Kw 415 V 50 Hz 1
5 Triple pole Contactor 240Vac 4
6 Batten type Lamp holder 240 Vac 105 A 4
7 Start stop button 240Vac 10A 4
8 Filament lamp (Bulb ) 240Vac 40W 4
9 DIN rail 35 mm As required
10 Flexible wires 1 mm As required
7 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
11 Single core PVC insulated
wire
25 mm As required
12 Terminal block 20 A As required
13 Squirrel cage motor 10kW 1
14 5 pin plug and socket 415V 20A 1
15 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a open transient autotransformer starter
b close transient autotransformer starter
c Forward reverse autotransformer starter
4 Test the functionality of completed project
8 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
Objectives
1 Identify component and the specification
2 Design rotor resistance starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
9 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Rotor Resistor set 10kW 1
5 Triple pole Contactor 240Vac 20A 4
6 Indicating light 240vac 5 A 4
7 Start stop push button 240Vac 5A 4
8 DIN rail 35 mm As required
9 Flexible wires 1 mm 2 As required
10 Single core PVC insulated wire 25 mm 2 As required
11 Terminal block 20 A As required
12 Slip Ring motor 10kW 1
13 5 pin round 3 phase socket 415V 20A 1
14 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
10 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
4 Test the functionality of completed project
a Dead circuit test b Life circuit test
5 Measure starting and running Amps
LESSON 16
TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
An installation in general will suffer damage
Damage usually occurs on the electric motor control as follows
1 Damage to the main circuit
2 Damage to the control circuit
The cause of the damage
i Overcurrent overload short circuit
ii Leakage current to ground
iii Equipment malfunction
iv The main control circuit
a Trip of main circuit protection devices fire
b Defect of motor terminal such as short circuit fire loose
v The control circuit is not functioning -
a contactor relay relay time overload relay does not work damaged burned
b Loose cable connection disconnected
Detecting and Repairing Damage
Examples of damage are as follows
i Motor does not work
ii Motor function and overload relay trips
iii Motor function but only partially functional control circuit
Methods of detecting damage
Among the known methods necessary to detect damage are as follows
1 Turn off the electricity at the main switch (main switch) in order to avoid any danger during the
work carried out to detect damage
2 Check all the protective gear that controls the motor control main circuit
11 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
3 Make sure the damage function control circuit
4 Check the control circuit according to the schematic circuit diagram of the motor control
5 Check the operation of the control circuit
Note
Use wiring that has been installed on the SYSTEM OF MOTOR CONTROL BOARD by Forward
Reverse control circuit for Star Delta to test and look for damage
SELF-ASSESSMENT QUESTIONS
1 (a) Explain what is meant by the term lsquoback emfrsquo in a motor
(b) Outline the basic differences between series shunt and compound wound dc motors
2 (a) With the aid of diagrams explain how the speed of series shunt and compound-wound motors
may be controlled
(b) A 440V dc shunt-wound motor has a field resistance of 200R and an armature resistance of 06 R
When its speed is 20 rev d second the current drawn from the supply is 122A Calculate its back
emf at this speed If the speed were decreased to 19 revssecond the field flux remaining unchanged
calculate the new back emf and the new armature current
3 A load of 64 kW at 240 V is supplied from the terminals of a shunt-wound dc generator The field
resistance is 180 A Calculate the armature current
4 (a) Explain with the aid of a diagram how a rotating magnetic field may be
(b) What is meant by lsquosynchronous speedrsquo
Calculate the synchronous obtained speed of a 12 pole motor if the supply frequency is 50Hz
5 (a) Explain the action of a synchronous motor
(b) What methods are available to start a synchronous motor Explain with diagrams
6 (a) Explain the action of a cage induction motor
(b) What is meant by the term lsquosliprsquo
Calculate the percentage slip of a six pole induction motor running at 162 revssecond from a 50 Hz
supply
7 Describe with sketches three different ways of starting a single-phase induction motor
12 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
8 Explain with the aid of a sketch the action of a three-phase DOL starter
What are dashpots used for How are remote start and stop buttons connected
9 A I0 kW 240V 50Hz single-phase cage rotor induction motor is 85efficient and has a PF of 068
lagging Calculate the motor current and the value of capacitor required to raise the PF to 093
lagging
10 Calculate the torque developed by an 18 kW four-pole induction motor run at 35 slip from a
50Hz supply
APPENDIX 1
13 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 11
14 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 111
Attachment Reference
httpswwwtlc-directcoukBook621htm
httpwwwstgovmyindexphpms
15 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
30 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
31 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 2 WIRING SYSTEM OF SINGLE PHASE LIGHTING CIRCUIT Introduction
Objectives
1 Identify component and the specification
2 Wire component according to the schematic diagram
3 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Wiring bay Perforated metal 180 cm x 180 cm 1
2 Cut out fuse 63 A 240 V 1
3 Neutral link 1
4 Single pole one way switch cw
switch box
5A 240Vac 4
5 single pole two way switch cw
switch box
5A 240Vac 2
6 RCCB In = 40 A Tripping current
100mA240 Vac 50 Hz
1
7 Main switch 32 A 240V 1
8 kWatthour meter 40 A 240 Vac 1
9 Single pole MCB 6A 240 Vac 1
10 Self tapping Wood screw As required
11 DIN rail 35 mm width As required
32 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
12 PVC trunking 50 mm x 50 mm As required
13 Terminal blocks 5 A As required
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
1 One way switch to control one lamp
2 One way switch to control two lamps
3 Two of two way switch to control one lamp
4 Two of single pole two way switch and one of an intermediate switch to control one
lamp
5 One unit of ceiling fan and fan regulator to be controlled by one way switch
4 Test the functionality of completed project
LESSON 3ndash WIRING SYSTEM OF SINGLE PHASE POWER CIRCUIT Introduction
33 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
34 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify types of component and its specification
2 Wire component according to the schematic diagram given
3 Test the functionality of the circuit dead circuit test life circuit test
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board Perforated Metal 1
2 kWh meter 240 V 40 A 1
3 Socket outlet 13A 240Vac 4
4 RCCB 40A Trip Amps
30mA240 Vac
1
5 3 pin socket 240Vac 13A 4
6 Single pole MCB 20A 240 V 2
7 DOL starter 1 kW 240Vac 2
8 1 phase induction motor 2Hp 240 Vac 1
9 Cooker control unit 4kW 240Vac 1
10 Water heater point 4kW 240 Vac 1
11 DIN rail 35 mm As required
12 PVC casing 20mm As required
13 Flexible wires 05 mm As required
14 Terminal block 10 A As required
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Wire two unit of 13 A socket outlet in radial circuit
3 Wire four units of 13 A socket outlet in ring circuit
4 Wire one unit DOL starter for air-conditioner point
5 Wire one unit of cooker control unit point
6 Wire one unit of water heater point
7 Test the functionality of each component by using mmeter or power supply whichever
applicable
8 Wire component according to circuit diagram
9 Test the functionality of completed project dead circuit test life circuit test
Note
35 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Ensure that the correct rating of protection device and size of wire used
LESSON 4ndash CONDUIT BENDING AND TRUNKING FABRICATION TECHNIQUE
Common fitting used in an industrial wiring
Cutting and threading the condute
36 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
37 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
38 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify conduit fitting and the specification
2 Measure and Cut steel conduit according to specified dimension
3 Bend and fabricate conduit at 45 90 according to layout diagram
4 Wire component according to the schematic diagram
5 Test the functionality of the circuit
39 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Conduit Bender Oslash 19 mm ( frac34 ldquo) 1
2 Measuring Tape 3 metre 1
3 Hacksaw frame and blade 30cm 1
4 Conduit cutter 1
5 Pipe Vise 1
6 Pipe Wrench 1
7 Ratchet Dies 20 mm 1
8 Metal trunking 50 mm x 50 mm 1
9 GI conduit 20mm 1
10 End box 20 mm 1
11 Flexible wires 05 mm As required
12 Connectors 5 A As required
13 Single core PVC ins Cable 25 mm 2 As required
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Wire two unit of 13 A socket outlet in radial circuit
3 Wire four unit of 13 A socket outlet in ring circuit
4 Wire one unit DOL starter for air-conditioner point
5 Wire one unit of cooker control unit point
6 Wire one unit of water heater point
7 Test the functionality of each component by using multimeter or power supply whichever
applicable
8 Wire component according to circuit diagram
9 Test the functionality of completed project
Note
Ensure that the rating of protection device and size of wire
K prior to 31 March
2004 (BS 7671)
(formerly)
bare conductor
sleeved at terminations (formerly)
40 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 5 ndashWIRING SYSTEM OF 1 Oslash LIGHTING AND POWER CIRCUIT
POWER CIRCUITSa Radial circuits
Radial circuits are arranged in the same way as item 1 above in lighting layouts in that each socket
outlet is supplied via the previous one
Points to note
1 The number of socket outlets complying with BS 1363 is unlimited for a floor area of up to 50m 2 if
the circuit protection is a 30 A or 32 A cartridge fuse or circuit breaker the cable being 4 mm PVC
copper or 25 mm2 mineral insulated (mi)
2 The number of socket outlets is unlimited for a floor area up to 20 m 2 with any type of circuit
protection of 20 A using 25 mm2 PVC copper cable or 15 mm2 mi
3 The total number of fused spurs is unlimited
b ring final circuits
These circuits are the same as radial circuits except that the final socket outlet is wired back to the
supply position In effect any outlet is supplied from two directions (Fig 152)
Points to note
1 Every twin-socket outlet counts as two single-socket outlets
2 The number of non-fused spurs must not exceed the total number of points on the ring Fig 158
shows seven points on the ring and five spurs
3 The fuse rating of a fused spur box must not exceed 13 A and the current rating of all points supplied
by the fused spur must not exceed 13 A
4 Non-fused spurs must supply no more than one single or one double socket on the ring Fig 158
shows seven points on the ring and five spurs rating of all points supplied by the fused spur must not
exceed 13 A or one stationary appliance
CapacityMain conductor size
copper (mm2)
Earth conductor
size (mm2)
Circuit breaker
capacity (A)
Up to 600 W 15 15 6
600ndash1200 W 1525 15 10
1200ndash1800 W 254 25 16
41 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Ring circuit
(floor area 100 m2)25 15 3032
A2 radial circuit
(floor area 75 m2)40 25 3032
A3 radial circuit
(floor area 50 m2)25 15 20
Air conditioner (15 tonne) 60 60 3032
Cooker 60 60 3032
Water heater 40 40 20
Objectives
1 Identify component and the specification
2 Wire component according to the schematic diagram
3 Test the functionality of the circuit
42 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board Perforated 1
2 Cut out fuse and neutral link 60A 240V 1each
3 kWh meter 240V 40A 1
4 Switched Socket outlet 13A 240Vac 4
5 Single pole two way switch cw switch
box
5A 240Vac 2
6 RCCB ELCB 63 A Tripping current 100mA
415 Vac
1
7 3 pin plug 240Vac 13A 4
8 Single pole MCB 20 A 2
9 Single pole MCB 6A 1
10 Single pole MCB 20A 2
11 DOL starter 240Vac 2
12 1 phase induction motor 2hp 240 Vac 1
13 Self tapping Wood screw As required
14 DIN rail Stainless steel allum35 mm As required
15 PVC pipe 20mm dia As required
16 End box 20 mm dia 4
17 Flexible wires 05 mm 2 As required
18 Connectors 5 A As required
Procedures
43 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
4 Test the functionality of completed project
LESSON 6 ndash WIRING SYSTEM OF 3 Oslash DISTRIBUTION BOARD
Introduction
44 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
45 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
46 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
47 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
48 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify each component and the specification
2 Wire component according to the schematic diagram given
3 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting Board 450 x 600 mm Perforated metal 1
2 5 pin round socket and plug 415V ac 32A 1
3 Cut out fuse 60 A 3
4 Neutral link 1
5 kWatt hour meter 415V 60A 1
6 ELCB RCCB 3P+N In=63A415 Vac I trip= 300mA 1
7 ELCB RCCB 3P+N In=63A415 Vac I trip= 30mA 1
8 Single pole MCB 6A 240 V 3
9 Single pole MCB 20A 240 V 3
10 DOL starter 20 A 240Vac 2
11 Socket outlet 15 A 240 Vac 1
12 Switched Socket outlet 13 A 240 Vac 3
13 Led indicating light 5A 240 Vac 3
14 Single pole 4 gang 1 way switch 5A 240 Vac 2
15 Single pole 2 way switch 5A 240 Vac 2
16 1 phase induction motor 1 kW 240Vac 1
17 Metal trunking 30 mm x30 mm As required
18 Self tapping Wood screw 4 mm x 20 mm As required
19 DIN rail 25 mm x 1mm
20 GI steel rigid conduit 20mm As required
21 Flexible conduit 20mm As required
22 End box 20 mm 4
23 Flexible wires 05 mm 2 As required
24 Single core PVC insulated wire 15 mm 2 As required
25 Single core PVC insulated wires 25 mm 2 As required
26 Terminal block 10 A As required
Procedures
49 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify each components and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
4 Test the functionality of completed project
1 dead circuit test
2 life circuit
Note Proper earthing should be made
50 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 7 ndash WIRING SYSTEM OF THREE PHASE LIGHTING AND POWER CIRCUIT
51 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
52 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify component and the specification
2 Wire component according to the schematic diagram
3 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting bay Board Perforated metal 180 cm x 180 cm 1
2 k Watt hour meter 415V 60A 1
3 MCCB 415V 60A
4 ELCB RCCB In=60A415 Vac I trip=30mA 1
5 5 pin round Socket and
plug
415Vac 32A 4
6 Single pole MCB 6A 1
7 Triple pole MCB 20A 2
8 Triple pole Main switch 60A 1
9 DOL starter 240Vac 2
10 3 phase induction motor 2hp 415 Vac 1
11 1 phase induction motor 1
12 Metal trunking 30 mm x30 mm As required
13 Self tapping Wood screw 4 mm x 20 mm As required
14 DIN rail 25 mm x 1mm
15 GI steel rigid conduit 20mm As required
16 Flexible conduit 20mm As required
17 End box 20 mm 4
18 Flexible wires 05 mm As required
19 Connectors 10 A As required
Procedures
1 Identify each components and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
4 Test the functionality of completed project
1 dead circuit 2 life circuit test
5 Record the current drawn by the load as connected in star and delta
Note Proper earthing should be made
53 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 8 INSPECTION AND TESTING OF ELECTRICAL INSTALLATION
On completion of a wiring installation a number of tests on the installation have to be conducted to
ascertain that the wiring circuits and connected appliances are safe for use Prior to carrying out the
tests an inspection has to be done The results of the inspectionsupervision and test have to be
presented in Form G (as in Appendix IV) and Form H (as in Appendix V)
To have the test certification as in Form H the following tests shall be conducted
i Continuity Test
ii Insulation Resistance Test
iii Polarity Test
iv Earth Electrode Resistance test and
v Residual Current Device Test
1 Continuity Test
There are 3 main types of continuity tests for the final circuits-
i Protection Conductor Continuity Test
ii Final Ring Circuit Conductor Continuity Test
iii Live and Neutral Conductor Continuity Test
a) Protection Conductor Continuity Test
bull To ascertain that all protection conductors are connected in the correct and effective manner
bull Test equipment ndash Multimeter (Ohm range) or Ohm meter
54 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
bull Test Method
1 1048766 Ensure that the main switch RCD and MCB are open circuited (switched off) and all loads
are disconnected
2 1048766 Connected the test leads as in the Figure 81 The meter reading shall be less than 1 Ω
55 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Final Ring Circuit Conductor Continuity Test
bull To ensure that all conductors around the ring circuit have continuity
bull Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
bull Test Method
1 1048766 Disconnect both the supply source live conductors from the MCB the neutral conductor
from the neutral terminals and the earth conductor from the earth terminal in the distribution
fuse box
2 1048766 Connect the test leads as in the Figure 82 (EE)
3 1048766 Repeat the procedure for (L-L) and (N-N)
4 1048766 The meter reading value shall be less than 1 ohm
56 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Live and Neutral Conductor Continuity Test
a To ensure that each conductor in the circuit has continuity
b Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
2 Test Method
1 1048766 Switch off the Main switch RCD and MCB
2 1048766 Disconnect all loads
3 1048766 Switch on all switches in the circuit
4 1048766 Disconnect the fusesfinal circuit breakers and close the circuit
5 1048766 Carry out the test as shown in Figure 83
6 1048766 The meter reading value shall be less than 1Ω
57 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
58 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
CONTINUITY TEST
Insulation Resistance Test
i Ensure that there is no leakage current between phase conductors phase and neutral conductors and
phase conductor and earth
ii Test the strength of the cable insulation
iii Test Equipment ndash Insulation Resistance Tester operating voltage is 250VDC or 500VDC
iv Test Method
1 1048766 Switch off main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
59 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
4 1048766 Carry out test as in the Table below
5 1048766 Meter reading value shall be less than 1 Megaohm
60 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
61 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Insulation resitance test
62 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
INSULATION RESISTANCE TEST BETWEEN CONDUCTORS AND OPPOSITE POLARITY
Polarity Testi Ensure that each fuse or single pole control and protection device is connected only in the phase
conductor
ii Intermediate contact of Edison screw lamp holder is connected to the phase conductor
iii Ensure that phase neutral and earth conductors at socket outlets are connected at the correct
terminals
iv Test Equipment ndash Multimeter (Ohm range) or Ohm meter
v Test Method
1 1048766 Switch off Main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in Figure 85
63 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
5 1048766 Test switches and single phase control devices at the phase conductors
6 1048766 Test socket outlet connection sources
7 1048766 Test Edison screw lamp holder connections
8 1048766 Meter reading value shall be less than 1 Ω
64 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Polarity test
65 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Earth Electrode Resistance Testi To test the earth electrode resistance
ii To ascertain the suitability of the location of the electrode
iii To ensure that the electrode is not buried within the resistance area of another electrode
iv Test equipment ndash Earth Resistance Tester
v Test method -
1 1048766 Terminal rsquoErsquo is connected to the electrode to be tested (green conductor)
2 1048766 Terminal lsquoPrsquo is connected to the potential spike (yellow conductor) at a distance of 10
meters from the earth electrode
3 1048766 Terminal lsquoCrsquo is connected to the current spike (red conductor) at a distance of 20 meters
from the earth electrode
Earth Electrode Resistance Measurement Method (Figure 86)
This test must be repeated at least three times to ensure that the reading is not affected by interacting
earthing regions
i Record the first reading (Z1) Example Z1 = 10 Ω
ii Move the voltage spike to a distance of 6 meters from the original position Record the second
reading (Z2 ) Example Z2 = 10 Ω
iii Move the voltage spike to a distance of 6 meters from the original position Record the third
reading (Z3) Example Z3 = 10 Ω
66 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Residual Current Device Testi Ensure that the residual current device (RCD) trips within the set time on the occurrence of current
leakage to earth
ii Test Equipment ndash RCD Tester RCCB Tester
iii Test Method 1
1 1048766 Use the Trip Test Button
2 1048766 Press the trip button found on the RCD to determine if it trips or otherwise This test would
not be able to determine the sensitivity of the RCD nor the time taken for it to trip
iv Test Method 2
i 1048766 Use a RCD Tester
ii This equipment is equipped with a 13A plug which can be connected to a 13A socket outlet
Select the RCD sensitivity to be the same as the sensitivity of the RCD to be tested to
determine if the RCD can trip The time to trip shall not exceed 40 mS
iii 1048766 Test method ndash
a) Position the selection switch in accordance with the sensitivity of the RCD used
Example 100 mA 01 A
b) Position the operations switch to lsquoNo Triprsquo (frac12 Rated mA = 50) connect the 3 pin plug to
the 13A socket outlet
67 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
c) Switch on the 13A socket outlet ndash ensure that the P-N and P-E lights light up
This shows that the polarity is correct (Note if both the lights as above do not light up the test cannot
be continued)
d) Press the test button ndash the reading shows less than 200 mS and simultaneously the lsquotestrsquo light lights
up and the P-N and P-E lights do not light up At that instant the RCD will not trip
e) Move the selection switch to 180o (+ve wave) ndash repeat steps (d) and (e) Move the operations
switch to lsquoTriprsquo (Rated mA = 100)
g) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200mS
h) Move the selection switch to 0o (-ve wave)
i) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
j) The above test is repeated until a near correct reading is obtained
k) Record the test results
l) Change the operations switch to lsquoFast Triprsquo and press the test button ndash RCD will trip within a
time not exceeding 40 millisecond
m) Repeat a number of times at 0o or 180o
On completion of a wiring installation a number of tests on the installation have to be conducted to
ascertain that the wiring circuits and connected appliances are safe for use Prior to carrying out the
tests an inspection has to be done the following tests shall be conducted
i Continuity Test
ii Insulation Resistance Test
iii Polarity Test
iv Earth Electrode Resistance test and
v Residual Current Device Test
821 Continuity Test
There are 3 main types of continuity tests for the final circuits-
i Protection Conductor Continuity Test
ii Final Ring Circuit Conductor Continuity Test
68 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
iii Live and Neutral Conductor Continuity Test
a) Protection Conductor Continuity Test
bull To ascertain that all protection conductors are connected in the correct and effective manner
bull Test equipment ndash Multimeter (Ohm range) or Ohm meter
bull Test Method
1 1048766 Ensure that the main switch RCD and MCB are open circuited (switched off) and all loads are
disconnected
2 1048766 Connected the test leads as in the Figure 81
3 1048766 The meter reading shall be less than 1 Ω
Final Ring Circuit Conductor Continuity Test
bull To ensure that all conductors around the ring circuit have continuity
bull Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
bull Test Method
1 1048766 Disconnect both the supply source live conductors from the MCB the neutral conductor
from the neutral terminals and the earth conductor from the earth terminal in the distribution
fuse box
2 1048766 Connect the test leads as in the Figure 82 (EE)
3 1048766 Repeat the procedure for (L-L) and (N-N)
4 1048766 The meter reading value shall be less than 1 ohm Figure 82 - Final Ring Circuit Conductor
Continuity Test Ohm Meter
Disconnect both the supply source cables from mcbfuse
Take readings at earth conductors of both sources and note resistance readings
Live and Neutral Conductor Continuity Test
1 To ensure that each conductor in the circuit has continuity
2 Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
3 Test Method
1 1048766 Switch off the Main switch RCD and MCB
2 1048766 Disconnect all loads
3 1048766 Switch on all switches in the circuit
4 1048766 Disconnect the fusesfinal circuit breakers and close the circuit
5 1048766 Carry out the test as shown in Figure 83
6 1048766 The meter reading value shall be less than 1 ohm Figure 83 - Live and Neutral
Conductor Continuity Test Ohm Meter
Insulation Resistance Test
69 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
i Ensure that there is no leakage current between phase conductors phase and neutral conductors and
phase conductor and earth
ii Test the strength of the cable insulation
iii Test Equipment ndash Insulation Resistance Tester Operating voltage is 250VDC or 500VDC
iv Test Method
1 1048766 Switch off main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in the Table below
5 1048766 Meter reading value shall be less than 1 Megaohm
Polarity Test
i Ensure that each fuse or single pole control and protection device is connected only in the phase
conductor
ii Intermediate contact of Edison screw lamp holder is connected to the phase conductor
iii Ensure that phase neutral and earth conductors at socket outlets are connected at the correct
terminals
iv Test Equipment ndash Multimeter (Ohm range) or Ohm meter
v Test Method
1 1048766 Switch off Main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in Figure 85
5 1048766 Test switches and single phase control devices at the phase conductors
6 1048766 Test socket outlet connection sources
7 1048766 Test Edison screw lamp holder connections
8 1048766 Meter reading value shall be less than 1 Ω
Earth Electrode Resistance Test
i To test the earth electrode resistance
70 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
ii To ascertain the suitability of the location of the electrode
iii To ensure that the electrode is not buried within the resistance area of another electrode
iv Test equipment ndash Earth Resistance Tester
v Test method -
1 1048766 Terminal rsquoErsquo is connected to the electrode to be tested (green conductor)
2 1048766 Terminal lsquoPrsquo is connected to the potential spike (yellow conductor) at a distance of 10
meters from the earth electrode
3 1048766 Terminal lsquoCrsquo is connected to the current spike (red conductor) at a distance of 20 meters
from the earth electrode E P C Electrode 10 meter 10 meter
Figure 86 ndash Earth Electrode Resistance Measurement Test Equipment
Earth Electrode Resistance Measurement Method (Figure 86)
This test must be repeated at least three times to ensure that the reading is not affected by interacting
earthing regions
i Record the first reading (Z1) Example Z1 = 10 Ω
ii Move the voltage spike to a distance of 6 meters from the original position Record the second
reading (Z2) Example Z2 = 10 Ω
iii Move the voltage spike to a distance of 6 meters from the original position Record the third
reading (Z3)
Example Z3 = 10 Ω
Residual Current Device Test
71 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
i Ensure that the residual current device (RCD) trips within the set time on the occurrence of current
leakage to earth
ii Test Equipment ndash RCD Tester RCCB Tester
iii Test Method 1
1 1048766 Use the Trip Test Button
2 1048766 Press the trip button found on the RCD to determine if it trips or otherwise This test would
not be able to determine the sensitivity of the RCD nor the time taken for it to trip
iv Test Method 2
1048766 Use a RCD Tester
This equipment is equipped with a 13A plug which can be connected to a 13A socket outlet Select the
RCD sensitivity to be the same as the sensitivity of the RCD to be tested to determine if the RCD can
trip The time to trip shall not exceed 40 mS
1048766 Test method ndash
a) Position the selection switch in accordance with the sensitivity of the RCD used
Example 100 mA 01 A
b) Position the operations switch to lsquoNo Triprsquo (frac12 Rated mA = 50) connect the 3 pin plug to
the 13A socket outlet
c) Switch on the 13A socket outlet ndash ensure that the P-N and P-E lights light up This shows that
the polarity is correct (Note if both the lights as above do not light up the test cannot be
continued)
d) Press the test button ndash the reading shows less than 200 millisecond and simultaneously the
lsquotestrsquo light lights up and the P-N and P-E lights do not light up At that instant the RCD will
not trip
e) Move the selection switch to 180o (+ve wave) ndash repeat steps (d) and (e) = 100)
f) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
g) Move the selection switch to 0o (-ve wave)
h) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
i) The above test is repeated until a near correct reading is obtained
j) Record the test results
k) Change the operations switch to lsquoFast Triprsquo and press the test button ndash RCD will trip within a
time not exceeding 40 mS
l) Repeat a number of times at 0o or 180o
72 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 9 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (DC)
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
73 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Start stop button 240Vac 5A 2
9 Filament lamp (Bulb ) 240Vac 40W 3
10 Overload Relay 415V 20A 3
11 Three phase induction motor 5 hp 3
12 Single phase step down transformer 2500VA 1
13 Single core PVC insulated Cable 1mm 2 As required
14 Single core PVC insulated Cable 25mm 2 As required
15 DIN rail 35 mm As required
16 PVC type Cable tray 50 mm x 50 mm As required
17 Cable ties 4 ldquo As required
18 Flexible wires 05 mm As required
19 PVC Connectors 5 A amp 20 A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the schematic
diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a optional exercise
i Simple DOL starter
ii Forward reverse DOL starter
iii Forward Reverse Dahlander motor
iv Three motors operated in sequence by DOL starter operated by manual push
button or time delay relay
74 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
a One loop per-cycle
b Continuous operation in a loop
c optional circuit design to represent the same task
v Only one out of three motors to be operated at a time (quiz)
4 Test the functionality of completed project
LESSON 10 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (AC)
75 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 1
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Lamp point 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
76 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
11 Overload Relay 415V 20A 3
12 Three phase induction
motor
5 hp 3
13 Single core PVC insulated
Cable
1mm 2 As required
14 Single core PVC insulated
Cable
25mm 2 As required
15 DIN rail 35 mm As required
16 PVC type Cable tray 50 mm x 50 mm As required
17 Cable ties 4 ldquo As required
18 Flexible wires 05 mm As required
19 PVC Connectors 5 A amp 20 A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the
schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram optional exercise
4 Simple DOL starter
5 Forward reverse DOL starter
6 Test the functionality of completed project
77 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 1
78 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
cm
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Indicating light 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
11 Overload Relay 415V 20A 3
12 Three phase induction motor 5 hp 3
13 Single phase step down
transformer
2500VA 1
14 Single core PVC insulated
Cable
1mm 2 As required
15 Single core PVC insulated
Cable
25mm 2 As required
16 DIN rail 35 mm As required
17 PVC type Cable tray 50 mm x 50 mm As required
18 Cable ties 4 ldquo As required
19 Flexible wires 05 mm As required
20 PVC Connectors 5 A amp 20 A 240 V As required
21 Single pole MCB 6A 240 V 1
22 Single pole MCB 2A 240 V 1
23 Triple pole MCB 20A 415 V 1
24 Mounting board 30 cm x 40 cm x 3
cm
1
25 Relay cw 11 pin socket 10 A 240 Vac 2
26 Time delay relay 10 A 240 Vac 3
27 Triple pole Contactor 20A 240Vac 3
28 Batten type Lamp holder 240Vac 10 A 3
29 Start stop button 240Vac 10A 2
30 Indicating light (Bulb ) 240Vac 25W 3
31 Overload Relay 415V 20A 1
32 Three phase dahlander type
induction motor
5 hp 1
33 Single phase step down
transformer
24024Vac
2500VA
1
79 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
34 Single core PVC insulated
Cable
1mm 2 As required
35 Single core PVC insulated
Cable
25mm 2 As required
36 DIN rail 35 mm As required
37 PVC type Cable tray 50 mm x 50 mm As required
38 Cable ties 4 ldquo As required
39 Flexible wires 075 mm As required
40 PVC Connectors 5 A amp 20 A 240 V As required
41 Terminal block 20A 240Vac As required
Procedures
5 Identify each component according to specification and quantity required from the schematic
diagram attached
6 Test the functionality of each component by using multi-meter or power supply whichever
applicable
7 Wire component according to circuit diagram
8 Three motors operated in sequence by DOL starter operated by manual push button or time
delay relay
a One loop per-cycle
b Continuous operation in a loop
c optional circuit design to represent the same task
d Only one out of three motors to be operated at a time (quiz)
9 Test the functionality of completed project
80 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
BASIC DESIGN INDUSTRIAL MOTOR CONTROL (SEQUENCE CONTROL)
THREE PHASE INDUCTION MOTOR OPERATED IN SEQUENCE BY DIRECT ON LINE
STARTER
LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
81 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
82 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Lcd lamp indicator 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
11 Overload Relay 415V 20A 3
12 Three phase induction motor 5 hp 3
13 Single phase step down transformer 2500VA 1
14 Single core PVC insulated Cable 1mm 2 As required
15 Single core PVC insulated Cable 25mm 2 As required
16 DIN rail 35 mm As required
17 PVC type Cable tray 50 mm x 50 mm As required
18 Cable ties 4 ldquo As required
19 Flexible wires 1 mm Oslash As required
20 PVC Terminal block 10A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the schematic
diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a optional exercise
i Forward Reverse dahlander motor
4 Test the functionality of completed project
83 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
THREE PHASE DAHLANDER TYPE INDUCTION MOTOR OPERATED FORWARD AND
REVERSE OPERATION BY DIRECT ON LINE STARTER
84 ndash 99EASYTECH ENTERPRISE
LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
Introduction
If a motors windings are connected in the star configuration any two phases will be in series across
the supply and hence the line current will be smaller(by 577) than if the windings were connected in
the delta arrangement
Hence larger-type motors with heavy starting currents are first connected in star and then when the
starting currents fall in delta This of course means that all six of the ends of the windings must be
brought to terminations outside the casing (Fig 833)
EZTECH
EZTECH ELECTRICAL INSTALLATION GUIDE
The automatic version of this starter incorporates a timing relay which automatically changes the
connections from star to delta Figs 834 and 835 show the wiring and schematic diagrams for a star
delta starter
Objectives
1 Identify component and the specification
2 Design forward reverse star delta starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
2 ndash 99EASYTECH ENTERPRISE
REV -C
LEGENDMCCB Moulded Case Circuit BreakerTOR Thermal Over Load RelayFOW-C Mains Forward ContactorREV-C Mains Reverse ContactorDC Delta ContactorSC Star ContactorS-SW Mains Selector Switch
SC
V2
W2
U2
DC
V1
W1
U1
TOR
TOR
FOW-C
30A MCCB
TOR
MAIN CIRCUIT FORWARD REVERSE STAR DELTA
RYBN S
-SW
3 PHASEINDUCTION MOTOR
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Relay 10 A 240V 3
5 Triple pole Contactor
6 cw NO NC auxiliary contact
240Vac 20 A 4
7 Overload Relay 415 V 1
8 LED indicator 240vac 5 A 4
9 Start stop button 240Vac 5A 2
10 DIN rail 35 mm As required
11 Flexible wires 1 mm As required
12 Single core PVC insulated
wire
25 mm As required
13 Terminal block 20 A As required
14 Squirrel cage motor 5kW 1
15 5 pin plug and socket 415V 20A 1
16 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
3 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
a Manual star delta
b Manual Forward reverse star delta starter
c Automatic star delta starter
d Automatic Forward reverse star delta starter
4 Test the functionality of completed project
4 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
Objectives
1 Identify component and the specification
2 Design auto transformer starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
5 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Autotransformer starter is used to start a 3 phase induction motor that has a rating between 10 to 15 hp
6 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Autotransformer set 10Kw 415 V 50 Hz 1
5 Triple pole Contactor 240Vac 4
6 Batten type Lamp holder 240 Vac 105 A 4
7 Start stop button 240Vac 10A 4
8 Filament lamp (Bulb ) 240Vac 40W 4
9 DIN rail 35 mm As required
10 Flexible wires 1 mm As required
7 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
11 Single core PVC insulated
wire
25 mm As required
12 Terminal block 20 A As required
13 Squirrel cage motor 10kW 1
14 5 pin plug and socket 415V 20A 1
15 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a open transient autotransformer starter
b close transient autotransformer starter
c Forward reverse autotransformer starter
4 Test the functionality of completed project
8 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
Objectives
1 Identify component and the specification
2 Design rotor resistance starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
9 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Rotor Resistor set 10kW 1
5 Triple pole Contactor 240Vac 20A 4
6 Indicating light 240vac 5 A 4
7 Start stop push button 240Vac 5A 4
8 DIN rail 35 mm As required
9 Flexible wires 1 mm 2 As required
10 Single core PVC insulated wire 25 mm 2 As required
11 Terminal block 20 A As required
12 Slip Ring motor 10kW 1
13 5 pin round 3 phase socket 415V 20A 1
14 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
10 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
4 Test the functionality of completed project
a Dead circuit test b Life circuit test
5 Measure starting and running Amps
LESSON 16
TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
An installation in general will suffer damage
Damage usually occurs on the electric motor control as follows
1 Damage to the main circuit
2 Damage to the control circuit
The cause of the damage
i Overcurrent overload short circuit
ii Leakage current to ground
iii Equipment malfunction
iv The main control circuit
a Trip of main circuit protection devices fire
b Defect of motor terminal such as short circuit fire loose
v The control circuit is not functioning -
a contactor relay relay time overload relay does not work damaged burned
b Loose cable connection disconnected
Detecting and Repairing Damage
Examples of damage are as follows
i Motor does not work
ii Motor function and overload relay trips
iii Motor function but only partially functional control circuit
Methods of detecting damage
Among the known methods necessary to detect damage are as follows
1 Turn off the electricity at the main switch (main switch) in order to avoid any danger during the
work carried out to detect damage
2 Check all the protective gear that controls the motor control main circuit
11 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
3 Make sure the damage function control circuit
4 Check the control circuit according to the schematic circuit diagram of the motor control
5 Check the operation of the control circuit
Note
Use wiring that has been installed on the SYSTEM OF MOTOR CONTROL BOARD by Forward
Reverse control circuit for Star Delta to test and look for damage
SELF-ASSESSMENT QUESTIONS
1 (a) Explain what is meant by the term lsquoback emfrsquo in a motor
(b) Outline the basic differences between series shunt and compound wound dc motors
2 (a) With the aid of diagrams explain how the speed of series shunt and compound-wound motors
may be controlled
(b) A 440V dc shunt-wound motor has a field resistance of 200R and an armature resistance of 06 R
When its speed is 20 rev d second the current drawn from the supply is 122A Calculate its back
emf at this speed If the speed were decreased to 19 revssecond the field flux remaining unchanged
calculate the new back emf and the new armature current
3 A load of 64 kW at 240 V is supplied from the terminals of a shunt-wound dc generator The field
resistance is 180 A Calculate the armature current
4 (a) Explain with the aid of a diagram how a rotating magnetic field may be
(b) What is meant by lsquosynchronous speedrsquo
Calculate the synchronous obtained speed of a 12 pole motor if the supply frequency is 50Hz
5 (a) Explain the action of a synchronous motor
(b) What methods are available to start a synchronous motor Explain with diagrams
6 (a) Explain the action of a cage induction motor
(b) What is meant by the term lsquosliprsquo
Calculate the percentage slip of a six pole induction motor running at 162 revssecond from a 50 Hz
supply
7 Describe with sketches three different ways of starting a single-phase induction motor
12 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
8 Explain with the aid of a sketch the action of a three-phase DOL starter
What are dashpots used for How are remote start and stop buttons connected
9 A I0 kW 240V 50Hz single-phase cage rotor induction motor is 85efficient and has a PF of 068
lagging Calculate the motor current and the value of capacitor required to raise the PF to 093
lagging
10 Calculate the torque developed by an 18 kW four-pole induction motor run at 35 slip from a
50Hz supply
APPENDIX 1
13 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 11
14 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 111
Attachment Reference
httpswwwtlc-directcoukBook621htm
httpwwwstgovmyindexphpms
15 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
31 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 2 WIRING SYSTEM OF SINGLE PHASE LIGHTING CIRCUIT Introduction
Objectives
1 Identify component and the specification
2 Wire component according to the schematic diagram
3 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Wiring bay Perforated metal 180 cm x 180 cm 1
2 Cut out fuse 63 A 240 V 1
3 Neutral link 1
4 Single pole one way switch cw
switch box
5A 240Vac 4
5 single pole two way switch cw
switch box
5A 240Vac 2
6 RCCB In = 40 A Tripping current
100mA240 Vac 50 Hz
1
7 Main switch 32 A 240V 1
8 kWatthour meter 40 A 240 Vac 1
9 Single pole MCB 6A 240 Vac 1
10 Self tapping Wood screw As required
11 DIN rail 35 mm width As required
32 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
12 PVC trunking 50 mm x 50 mm As required
13 Terminal blocks 5 A As required
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
1 One way switch to control one lamp
2 One way switch to control two lamps
3 Two of two way switch to control one lamp
4 Two of single pole two way switch and one of an intermediate switch to control one
lamp
5 One unit of ceiling fan and fan regulator to be controlled by one way switch
4 Test the functionality of completed project
LESSON 3ndash WIRING SYSTEM OF SINGLE PHASE POWER CIRCUIT Introduction
33 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
34 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify types of component and its specification
2 Wire component according to the schematic diagram given
3 Test the functionality of the circuit dead circuit test life circuit test
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board Perforated Metal 1
2 kWh meter 240 V 40 A 1
3 Socket outlet 13A 240Vac 4
4 RCCB 40A Trip Amps
30mA240 Vac
1
5 3 pin socket 240Vac 13A 4
6 Single pole MCB 20A 240 V 2
7 DOL starter 1 kW 240Vac 2
8 1 phase induction motor 2Hp 240 Vac 1
9 Cooker control unit 4kW 240Vac 1
10 Water heater point 4kW 240 Vac 1
11 DIN rail 35 mm As required
12 PVC casing 20mm As required
13 Flexible wires 05 mm As required
14 Terminal block 10 A As required
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Wire two unit of 13 A socket outlet in radial circuit
3 Wire four units of 13 A socket outlet in ring circuit
4 Wire one unit DOL starter for air-conditioner point
5 Wire one unit of cooker control unit point
6 Wire one unit of water heater point
7 Test the functionality of each component by using mmeter or power supply whichever
applicable
8 Wire component according to circuit diagram
9 Test the functionality of completed project dead circuit test life circuit test
Note
35 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Ensure that the correct rating of protection device and size of wire used
LESSON 4ndash CONDUIT BENDING AND TRUNKING FABRICATION TECHNIQUE
Common fitting used in an industrial wiring
Cutting and threading the condute
36 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
37 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
38 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify conduit fitting and the specification
2 Measure and Cut steel conduit according to specified dimension
3 Bend and fabricate conduit at 45 90 according to layout diagram
4 Wire component according to the schematic diagram
5 Test the functionality of the circuit
39 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Conduit Bender Oslash 19 mm ( frac34 ldquo) 1
2 Measuring Tape 3 metre 1
3 Hacksaw frame and blade 30cm 1
4 Conduit cutter 1
5 Pipe Vise 1
6 Pipe Wrench 1
7 Ratchet Dies 20 mm 1
8 Metal trunking 50 mm x 50 mm 1
9 GI conduit 20mm 1
10 End box 20 mm 1
11 Flexible wires 05 mm As required
12 Connectors 5 A As required
13 Single core PVC ins Cable 25 mm 2 As required
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Wire two unit of 13 A socket outlet in radial circuit
3 Wire four unit of 13 A socket outlet in ring circuit
4 Wire one unit DOL starter for air-conditioner point
5 Wire one unit of cooker control unit point
6 Wire one unit of water heater point
7 Test the functionality of each component by using multimeter or power supply whichever
applicable
8 Wire component according to circuit diagram
9 Test the functionality of completed project
Note
Ensure that the rating of protection device and size of wire
K prior to 31 March
2004 (BS 7671)
(formerly)
bare conductor
sleeved at terminations (formerly)
40 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 5 ndashWIRING SYSTEM OF 1 Oslash LIGHTING AND POWER CIRCUIT
POWER CIRCUITSa Radial circuits
Radial circuits are arranged in the same way as item 1 above in lighting layouts in that each socket
outlet is supplied via the previous one
Points to note
1 The number of socket outlets complying with BS 1363 is unlimited for a floor area of up to 50m 2 if
the circuit protection is a 30 A or 32 A cartridge fuse or circuit breaker the cable being 4 mm PVC
copper or 25 mm2 mineral insulated (mi)
2 The number of socket outlets is unlimited for a floor area up to 20 m 2 with any type of circuit
protection of 20 A using 25 mm2 PVC copper cable or 15 mm2 mi
3 The total number of fused spurs is unlimited
b ring final circuits
These circuits are the same as radial circuits except that the final socket outlet is wired back to the
supply position In effect any outlet is supplied from two directions (Fig 152)
Points to note
1 Every twin-socket outlet counts as two single-socket outlets
2 The number of non-fused spurs must not exceed the total number of points on the ring Fig 158
shows seven points on the ring and five spurs
3 The fuse rating of a fused spur box must not exceed 13 A and the current rating of all points supplied
by the fused spur must not exceed 13 A
4 Non-fused spurs must supply no more than one single or one double socket on the ring Fig 158
shows seven points on the ring and five spurs rating of all points supplied by the fused spur must not
exceed 13 A or one stationary appliance
CapacityMain conductor size
copper (mm2)
Earth conductor
size (mm2)
Circuit breaker
capacity (A)
Up to 600 W 15 15 6
600ndash1200 W 1525 15 10
1200ndash1800 W 254 25 16
41 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Ring circuit
(floor area 100 m2)25 15 3032
A2 radial circuit
(floor area 75 m2)40 25 3032
A3 radial circuit
(floor area 50 m2)25 15 20
Air conditioner (15 tonne) 60 60 3032
Cooker 60 60 3032
Water heater 40 40 20
Objectives
1 Identify component and the specification
2 Wire component according to the schematic diagram
3 Test the functionality of the circuit
42 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board Perforated 1
2 Cut out fuse and neutral link 60A 240V 1each
3 kWh meter 240V 40A 1
4 Switched Socket outlet 13A 240Vac 4
5 Single pole two way switch cw switch
box
5A 240Vac 2
6 RCCB ELCB 63 A Tripping current 100mA
415 Vac
1
7 3 pin plug 240Vac 13A 4
8 Single pole MCB 20 A 2
9 Single pole MCB 6A 1
10 Single pole MCB 20A 2
11 DOL starter 240Vac 2
12 1 phase induction motor 2hp 240 Vac 1
13 Self tapping Wood screw As required
14 DIN rail Stainless steel allum35 mm As required
15 PVC pipe 20mm dia As required
16 End box 20 mm dia 4
17 Flexible wires 05 mm 2 As required
18 Connectors 5 A As required
Procedures
43 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
4 Test the functionality of completed project
LESSON 6 ndash WIRING SYSTEM OF 3 Oslash DISTRIBUTION BOARD
Introduction
44 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
45 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
46 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
47 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
48 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify each component and the specification
2 Wire component according to the schematic diagram given
3 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting Board 450 x 600 mm Perforated metal 1
2 5 pin round socket and plug 415V ac 32A 1
3 Cut out fuse 60 A 3
4 Neutral link 1
5 kWatt hour meter 415V 60A 1
6 ELCB RCCB 3P+N In=63A415 Vac I trip= 300mA 1
7 ELCB RCCB 3P+N In=63A415 Vac I trip= 30mA 1
8 Single pole MCB 6A 240 V 3
9 Single pole MCB 20A 240 V 3
10 DOL starter 20 A 240Vac 2
11 Socket outlet 15 A 240 Vac 1
12 Switched Socket outlet 13 A 240 Vac 3
13 Led indicating light 5A 240 Vac 3
14 Single pole 4 gang 1 way switch 5A 240 Vac 2
15 Single pole 2 way switch 5A 240 Vac 2
16 1 phase induction motor 1 kW 240Vac 1
17 Metal trunking 30 mm x30 mm As required
18 Self tapping Wood screw 4 mm x 20 mm As required
19 DIN rail 25 mm x 1mm
20 GI steel rigid conduit 20mm As required
21 Flexible conduit 20mm As required
22 End box 20 mm 4
23 Flexible wires 05 mm 2 As required
24 Single core PVC insulated wire 15 mm 2 As required
25 Single core PVC insulated wires 25 mm 2 As required
26 Terminal block 10 A As required
Procedures
49 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify each components and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
4 Test the functionality of completed project
1 dead circuit test
2 life circuit
Note Proper earthing should be made
50 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 7 ndash WIRING SYSTEM OF THREE PHASE LIGHTING AND POWER CIRCUIT
51 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
52 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify component and the specification
2 Wire component according to the schematic diagram
3 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting bay Board Perforated metal 180 cm x 180 cm 1
2 k Watt hour meter 415V 60A 1
3 MCCB 415V 60A
4 ELCB RCCB In=60A415 Vac I trip=30mA 1
5 5 pin round Socket and
plug
415Vac 32A 4
6 Single pole MCB 6A 1
7 Triple pole MCB 20A 2
8 Triple pole Main switch 60A 1
9 DOL starter 240Vac 2
10 3 phase induction motor 2hp 415 Vac 1
11 1 phase induction motor 1
12 Metal trunking 30 mm x30 mm As required
13 Self tapping Wood screw 4 mm x 20 mm As required
14 DIN rail 25 mm x 1mm
15 GI steel rigid conduit 20mm As required
16 Flexible conduit 20mm As required
17 End box 20 mm 4
18 Flexible wires 05 mm As required
19 Connectors 10 A As required
Procedures
1 Identify each components and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
4 Test the functionality of completed project
1 dead circuit 2 life circuit test
5 Record the current drawn by the load as connected in star and delta
Note Proper earthing should be made
53 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 8 INSPECTION AND TESTING OF ELECTRICAL INSTALLATION
On completion of a wiring installation a number of tests on the installation have to be conducted to
ascertain that the wiring circuits and connected appliances are safe for use Prior to carrying out the
tests an inspection has to be done The results of the inspectionsupervision and test have to be
presented in Form G (as in Appendix IV) and Form H (as in Appendix V)
To have the test certification as in Form H the following tests shall be conducted
i Continuity Test
ii Insulation Resistance Test
iii Polarity Test
iv Earth Electrode Resistance test and
v Residual Current Device Test
1 Continuity Test
There are 3 main types of continuity tests for the final circuits-
i Protection Conductor Continuity Test
ii Final Ring Circuit Conductor Continuity Test
iii Live and Neutral Conductor Continuity Test
a) Protection Conductor Continuity Test
bull To ascertain that all protection conductors are connected in the correct and effective manner
bull Test equipment ndash Multimeter (Ohm range) or Ohm meter
54 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
bull Test Method
1 1048766 Ensure that the main switch RCD and MCB are open circuited (switched off) and all loads
are disconnected
2 1048766 Connected the test leads as in the Figure 81 The meter reading shall be less than 1 Ω
55 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Final Ring Circuit Conductor Continuity Test
bull To ensure that all conductors around the ring circuit have continuity
bull Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
bull Test Method
1 1048766 Disconnect both the supply source live conductors from the MCB the neutral conductor
from the neutral terminals and the earth conductor from the earth terminal in the distribution
fuse box
2 1048766 Connect the test leads as in the Figure 82 (EE)
3 1048766 Repeat the procedure for (L-L) and (N-N)
4 1048766 The meter reading value shall be less than 1 ohm
56 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Live and Neutral Conductor Continuity Test
a To ensure that each conductor in the circuit has continuity
b Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
2 Test Method
1 1048766 Switch off the Main switch RCD and MCB
2 1048766 Disconnect all loads
3 1048766 Switch on all switches in the circuit
4 1048766 Disconnect the fusesfinal circuit breakers and close the circuit
5 1048766 Carry out the test as shown in Figure 83
6 1048766 The meter reading value shall be less than 1Ω
57 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
58 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
CONTINUITY TEST
Insulation Resistance Test
i Ensure that there is no leakage current between phase conductors phase and neutral conductors and
phase conductor and earth
ii Test the strength of the cable insulation
iii Test Equipment ndash Insulation Resistance Tester operating voltage is 250VDC or 500VDC
iv Test Method
1 1048766 Switch off main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
59 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
4 1048766 Carry out test as in the Table below
5 1048766 Meter reading value shall be less than 1 Megaohm
60 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
61 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Insulation resitance test
62 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
INSULATION RESISTANCE TEST BETWEEN CONDUCTORS AND OPPOSITE POLARITY
Polarity Testi Ensure that each fuse or single pole control and protection device is connected only in the phase
conductor
ii Intermediate contact of Edison screw lamp holder is connected to the phase conductor
iii Ensure that phase neutral and earth conductors at socket outlets are connected at the correct
terminals
iv Test Equipment ndash Multimeter (Ohm range) or Ohm meter
v Test Method
1 1048766 Switch off Main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in Figure 85
63 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
5 1048766 Test switches and single phase control devices at the phase conductors
6 1048766 Test socket outlet connection sources
7 1048766 Test Edison screw lamp holder connections
8 1048766 Meter reading value shall be less than 1 Ω
64 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Polarity test
65 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Earth Electrode Resistance Testi To test the earth electrode resistance
ii To ascertain the suitability of the location of the electrode
iii To ensure that the electrode is not buried within the resistance area of another electrode
iv Test equipment ndash Earth Resistance Tester
v Test method -
1 1048766 Terminal rsquoErsquo is connected to the electrode to be tested (green conductor)
2 1048766 Terminal lsquoPrsquo is connected to the potential spike (yellow conductor) at a distance of 10
meters from the earth electrode
3 1048766 Terminal lsquoCrsquo is connected to the current spike (red conductor) at a distance of 20 meters
from the earth electrode
Earth Electrode Resistance Measurement Method (Figure 86)
This test must be repeated at least three times to ensure that the reading is not affected by interacting
earthing regions
i Record the first reading (Z1) Example Z1 = 10 Ω
ii Move the voltage spike to a distance of 6 meters from the original position Record the second
reading (Z2 ) Example Z2 = 10 Ω
iii Move the voltage spike to a distance of 6 meters from the original position Record the third
reading (Z3) Example Z3 = 10 Ω
66 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Residual Current Device Testi Ensure that the residual current device (RCD) trips within the set time on the occurrence of current
leakage to earth
ii Test Equipment ndash RCD Tester RCCB Tester
iii Test Method 1
1 1048766 Use the Trip Test Button
2 1048766 Press the trip button found on the RCD to determine if it trips or otherwise This test would
not be able to determine the sensitivity of the RCD nor the time taken for it to trip
iv Test Method 2
i 1048766 Use a RCD Tester
ii This equipment is equipped with a 13A plug which can be connected to a 13A socket outlet
Select the RCD sensitivity to be the same as the sensitivity of the RCD to be tested to
determine if the RCD can trip The time to trip shall not exceed 40 mS
iii 1048766 Test method ndash
a) Position the selection switch in accordance with the sensitivity of the RCD used
Example 100 mA 01 A
b) Position the operations switch to lsquoNo Triprsquo (frac12 Rated mA = 50) connect the 3 pin plug to
the 13A socket outlet
67 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
c) Switch on the 13A socket outlet ndash ensure that the P-N and P-E lights light up
This shows that the polarity is correct (Note if both the lights as above do not light up the test cannot
be continued)
d) Press the test button ndash the reading shows less than 200 mS and simultaneously the lsquotestrsquo light lights
up and the P-N and P-E lights do not light up At that instant the RCD will not trip
e) Move the selection switch to 180o (+ve wave) ndash repeat steps (d) and (e) Move the operations
switch to lsquoTriprsquo (Rated mA = 100)
g) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200mS
h) Move the selection switch to 0o (-ve wave)
i) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
j) The above test is repeated until a near correct reading is obtained
k) Record the test results
l) Change the operations switch to lsquoFast Triprsquo and press the test button ndash RCD will trip within a
time not exceeding 40 millisecond
m) Repeat a number of times at 0o or 180o
On completion of a wiring installation a number of tests on the installation have to be conducted to
ascertain that the wiring circuits and connected appliances are safe for use Prior to carrying out the
tests an inspection has to be done the following tests shall be conducted
i Continuity Test
ii Insulation Resistance Test
iii Polarity Test
iv Earth Electrode Resistance test and
v Residual Current Device Test
821 Continuity Test
There are 3 main types of continuity tests for the final circuits-
i Protection Conductor Continuity Test
ii Final Ring Circuit Conductor Continuity Test
68 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
iii Live and Neutral Conductor Continuity Test
a) Protection Conductor Continuity Test
bull To ascertain that all protection conductors are connected in the correct and effective manner
bull Test equipment ndash Multimeter (Ohm range) or Ohm meter
bull Test Method
1 1048766 Ensure that the main switch RCD and MCB are open circuited (switched off) and all loads are
disconnected
2 1048766 Connected the test leads as in the Figure 81
3 1048766 The meter reading shall be less than 1 Ω
Final Ring Circuit Conductor Continuity Test
bull To ensure that all conductors around the ring circuit have continuity
bull Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
bull Test Method
1 1048766 Disconnect both the supply source live conductors from the MCB the neutral conductor
from the neutral terminals and the earth conductor from the earth terminal in the distribution
fuse box
2 1048766 Connect the test leads as in the Figure 82 (EE)
3 1048766 Repeat the procedure for (L-L) and (N-N)
4 1048766 The meter reading value shall be less than 1 ohm Figure 82 - Final Ring Circuit Conductor
Continuity Test Ohm Meter
Disconnect both the supply source cables from mcbfuse
Take readings at earth conductors of both sources and note resistance readings
Live and Neutral Conductor Continuity Test
1 To ensure that each conductor in the circuit has continuity
2 Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
3 Test Method
1 1048766 Switch off the Main switch RCD and MCB
2 1048766 Disconnect all loads
3 1048766 Switch on all switches in the circuit
4 1048766 Disconnect the fusesfinal circuit breakers and close the circuit
5 1048766 Carry out the test as shown in Figure 83
6 1048766 The meter reading value shall be less than 1 ohm Figure 83 - Live and Neutral
Conductor Continuity Test Ohm Meter
Insulation Resistance Test
69 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
i Ensure that there is no leakage current between phase conductors phase and neutral conductors and
phase conductor and earth
ii Test the strength of the cable insulation
iii Test Equipment ndash Insulation Resistance Tester Operating voltage is 250VDC or 500VDC
iv Test Method
1 1048766 Switch off main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in the Table below
5 1048766 Meter reading value shall be less than 1 Megaohm
Polarity Test
i Ensure that each fuse or single pole control and protection device is connected only in the phase
conductor
ii Intermediate contact of Edison screw lamp holder is connected to the phase conductor
iii Ensure that phase neutral and earth conductors at socket outlets are connected at the correct
terminals
iv Test Equipment ndash Multimeter (Ohm range) or Ohm meter
v Test Method
1 1048766 Switch off Main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in Figure 85
5 1048766 Test switches and single phase control devices at the phase conductors
6 1048766 Test socket outlet connection sources
7 1048766 Test Edison screw lamp holder connections
8 1048766 Meter reading value shall be less than 1 Ω
Earth Electrode Resistance Test
i To test the earth electrode resistance
70 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
ii To ascertain the suitability of the location of the electrode
iii To ensure that the electrode is not buried within the resistance area of another electrode
iv Test equipment ndash Earth Resistance Tester
v Test method -
1 1048766 Terminal rsquoErsquo is connected to the electrode to be tested (green conductor)
2 1048766 Terminal lsquoPrsquo is connected to the potential spike (yellow conductor) at a distance of 10
meters from the earth electrode
3 1048766 Terminal lsquoCrsquo is connected to the current spike (red conductor) at a distance of 20 meters
from the earth electrode E P C Electrode 10 meter 10 meter
Figure 86 ndash Earth Electrode Resistance Measurement Test Equipment
Earth Electrode Resistance Measurement Method (Figure 86)
This test must be repeated at least three times to ensure that the reading is not affected by interacting
earthing regions
i Record the first reading (Z1) Example Z1 = 10 Ω
ii Move the voltage spike to a distance of 6 meters from the original position Record the second
reading (Z2) Example Z2 = 10 Ω
iii Move the voltage spike to a distance of 6 meters from the original position Record the third
reading (Z3)
Example Z3 = 10 Ω
Residual Current Device Test
71 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
i Ensure that the residual current device (RCD) trips within the set time on the occurrence of current
leakage to earth
ii Test Equipment ndash RCD Tester RCCB Tester
iii Test Method 1
1 1048766 Use the Trip Test Button
2 1048766 Press the trip button found on the RCD to determine if it trips or otherwise This test would
not be able to determine the sensitivity of the RCD nor the time taken for it to trip
iv Test Method 2
1048766 Use a RCD Tester
This equipment is equipped with a 13A plug which can be connected to a 13A socket outlet Select the
RCD sensitivity to be the same as the sensitivity of the RCD to be tested to determine if the RCD can
trip The time to trip shall not exceed 40 mS
1048766 Test method ndash
a) Position the selection switch in accordance with the sensitivity of the RCD used
Example 100 mA 01 A
b) Position the operations switch to lsquoNo Triprsquo (frac12 Rated mA = 50) connect the 3 pin plug to
the 13A socket outlet
c) Switch on the 13A socket outlet ndash ensure that the P-N and P-E lights light up This shows that
the polarity is correct (Note if both the lights as above do not light up the test cannot be
continued)
d) Press the test button ndash the reading shows less than 200 millisecond and simultaneously the
lsquotestrsquo light lights up and the P-N and P-E lights do not light up At that instant the RCD will
not trip
e) Move the selection switch to 180o (+ve wave) ndash repeat steps (d) and (e) = 100)
f) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
g) Move the selection switch to 0o (-ve wave)
h) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
i) The above test is repeated until a near correct reading is obtained
j) Record the test results
k) Change the operations switch to lsquoFast Triprsquo and press the test button ndash RCD will trip within a
time not exceeding 40 mS
l) Repeat a number of times at 0o or 180o
72 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 9 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (DC)
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
73 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Start stop button 240Vac 5A 2
9 Filament lamp (Bulb ) 240Vac 40W 3
10 Overload Relay 415V 20A 3
11 Three phase induction motor 5 hp 3
12 Single phase step down transformer 2500VA 1
13 Single core PVC insulated Cable 1mm 2 As required
14 Single core PVC insulated Cable 25mm 2 As required
15 DIN rail 35 mm As required
16 PVC type Cable tray 50 mm x 50 mm As required
17 Cable ties 4 ldquo As required
18 Flexible wires 05 mm As required
19 PVC Connectors 5 A amp 20 A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the schematic
diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a optional exercise
i Simple DOL starter
ii Forward reverse DOL starter
iii Forward Reverse Dahlander motor
iv Three motors operated in sequence by DOL starter operated by manual push
button or time delay relay
74 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
a One loop per-cycle
b Continuous operation in a loop
c optional circuit design to represent the same task
v Only one out of three motors to be operated at a time (quiz)
4 Test the functionality of completed project
LESSON 10 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (AC)
75 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 1
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Lamp point 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
76 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
11 Overload Relay 415V 20A 3
12 Three phase induction
motor
5 hp 3
13 Single core PVC insulated
Cable
1mm 2 As required
14 Single core PVC insulated
Cable
25mm 2 As required
15 DIN rail 35 mm As required
16 PVC type Cable tray 50 mm x 50 mm As required
17 Cable ties 4 ldquo As required
18 Flexible wires 05 mm As required
19 PVC Connectors 5 A amp 20 A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the
schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram optional exercise
4 Simple DOL starter
5 Forward reverse DOL starter
6 Test the functionality of completed project
77 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 1
78 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
cm
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Indicating light 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
11 Overload Relay 415V 20A 3
12 Three phase induction motor 5 hp 3
13 Single phase step down
transformer
2500VA 1
14 Single core PVC insulated
Cable
1mm 2 As required
15 Single core PVC insulated
Cable
25mm 2 As required
16 DIN rail 35 mm As required
17 PVC type Cable tray 50 mm x 50 mm As required
18 Cable ties 4 ldquo As required
19 Flexible wires 05 mm As required
20 PVC Connectors 5 A amp 20 A 240 V As required
21 Single pole MCB 6A 240 V 1
22 Single pole MCB 2A 240 V 1
23 Triple pole MCB 20A 415 V 1
24 Mounting board 30 cm x 40 cm x 3
cm
1
25 Relay cw 11 pin socket 10 A 240 Vac 2
26 Time delay relay 10 A 240 Vac 3
27 Triple pole Contactor 20A 240Vac 3
28 Batten type Lamp holder 240Vac 10 A 3
29 Start stop button 240Vac 10A 2
30 Indicating light (Bulb ) 240Vac 25W 3
31 Overload Relay 415V 20A 1
32 Three phase dahlander type
induction motor
5 hp 1
33 Single phase step down
transformer
24024Vac
2500VA
1
79 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
34 Single core PVC insulated
Cable
1mm 2 As required
35 Single core PVC insulated
Cable
25mm 2 As required
36 DIN rail 35 mm As required
37 PVC type Cable tray 50 mm x 50 mm As required
38 Cable ties 4 ldquo As required
39 Flexible wires 075 mm As required
40 PVC Connectors 5 A amp 20 A 240 V As required
41 Terminal block 20A 240Vac As required
Procedures
5 Identify each component according to specification and quantity required from the schematic
diagram attached
6 Test the functionality of each component by using multi-meter or power supply whichever
applicable
7 Wire component according to circuit diagram
8 Three motors operated in sequence by DOL starter operated by manual push button or time
delay relay
a One loop per-cycle
b Continuous operation in a loop
c optional circuit design to represent the same task
d Only one out of three motors to be operated at a time (quiz)
9 Test the functionality of completed project
80 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
BASIC DESIGN INDUSTRIAL MOTOR CONTROL (SEQUENCE CONTROL)
THREE PHASE INDUCTION MOTOR OPERATED IN SEQUENCE BY DIRECT ON LINE
STARTER
LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
81 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
82 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Lcd lamp indicator 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
11 Overload Relay 415V 20A 3
12 Three phase induction motor 5 hp 3
13 Single phase step down transformer 2500VA 1
14 Single core PVC insulated Cable 1mm 2 As required
15 Single core PVC insulated Cable 25mm 2 As required
16 DIN rail 35 mm As required
17 PVC type Cable tray 50 mm x 50 mm As required
18 Cable ties 4 ldquo As required
19 Flexible wires 1 mm Oslash As required
20 PVC Terminal block 10A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the schematic
diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a optional exercise
i Forward Reverse dahlander motor
4 Test the functionality of completed project
83 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
THREE PHASE DAHLANDER TYPE INDUCTION MOTOR OPERATED FORWARD AND
REVERSE OPERATION BY DIRECT ON LINE STARTER
84 ndash 99EASYTECH ENTERPRISE
LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
Introduction
If a motors windings are connected in the star configuration any two phases will be in series across
the supply and hence the line current will be smaller(by 577) than if the windings were connected in
the delta arrangement
Hence larger-type motors with heavy starting currents are first connected in star and then when the
starting currents fall in delta This of course means that all six of the ends of the windings must be
brought to terminations outside the casing (Fig 833)
EZTECH
EZTECH ELECTRICAL INSTALLATION GUIDE
The automatic version of this starter incorporates a timing relay which automatically changes the
connections from star to delta Figs 834 and 835 show the wiring and schematic diagrams for a star
delta starter
Objectives
1 Identify component and the specification
2 Design forward reverse star delta starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
2 ndash 99EASYTECH ENTERPRISE
REV -C
LEGENDMCCB Moulded Case Circuit BreakerTOR Thermal Over Load RelayFOW-C Mains Forward ContactorREV-C Mains Reverse ContactorDC Delta ContactorSC Star ContactorS-SW Mains Selector Switch
SC
V2
W2
U2
DC
V1
W1
U1
TOR
TOR
FOW-C
30A MCCB
TOR
MAIN CIRCUIT FORWARD REVERSE STAR DELTA
RYBN S
-SW
3 PHASEINDUCTION MOTOR
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Relay 10 A 240V 3
5 Triple pole Contactor
6 cw NO NC auxiliary contact
240Vac 20 A 4
7 Overload Relay 415 V 1
8 LED indicator 240vac 5 A 4
9 Start stop button 240Vac 5A 2
10 DIN rail 35 mm As required
11 Flexible wires 1 mm As required
12 Single core PVC insulated
wire
25 mm As required
13 Terminal block 20 A As required
14 Squirrel cage motor 5kW 1
15 5 pin plug and socket 415V 20A 1
16 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
3 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
a Manual star delta
b Manual Forward reverse star delta starter
c Automatic star delta starter
d Automatic Forward reverse star delta starter
4 Test the functionality of completed project
4 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
Objectives
1 Identify component and the specification
2 Design auto transformer starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
5 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Autotransformer starter is used to start a 3 phase induction motor that has a rating between 10 to 15 hp
6 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Autotransformer set 10Kw 415 V 50 Hz 1
5 Triple pole Contactor 240Vac 4
6 Batten type Lamp holder 240 Vac 105 A 4
7 Start stop button 240Vac 10A 4
8 Filament lamp (Bulb ) 240Vac 40W 4
9 DIN rail 35 mm As required
10 Flexible wires 1 mm As required
7 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
11 Single core PVC insulated
wire
25 mm As required
12 Terminal block 20 A As required
13 Squirrel cage motor 10kW 1
14 5 pin plug and socket 415V 20A 1
15 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a open transient autotransformer starter
b close transient autotransformer starter
c Forward reverse autotransformer starter
4 Test the functionality of completed project
8 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
Objectives
1 Identify component and the specification
2 Design rotor resistance starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
9 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Rotor Resistor set 10kW 1
5 Triple pole Contactor 240Vac 20A 4
6 Indicating light 240vac 5 A 4
7 Start stop push button 240Vac 5A 4
8 DIN rail 35 mm As required
9 Flexible wires 1 mm 2 As required
10 Single core PVC insulated wire 25 mm 2 As required
11 Terminal block 20 A As required
12 Slip Ring motor 10kW 1
13 5 pin round 3 phase socket 415V 20A 1
14 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
10 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
4 Test the functionality of completed project
a Dead circuit test b Life circuit test
5 Measure starting and running Amps
LESSON 16
TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
An installation in general will suffer damage
Damage usually occurs on the electric motor control as follows
1 Damage to the main circuit
2 Damage to the control circuit
The cause of the damage
i Overcurrent overload short circuit
ii Leakage current to ground
iii Equipment malfunction
iv The main control circuit
a Trip of main circuit protection devices fire
b Defect of motor terminal such as short circuit fire loose
v The control circuit is not functioning -
a contactor relay relay time overload relay does not work damaged burned
b Loose cable connection disconnected
Detecting and Repairing Damage
Examples of damage are as follows
i Motor does not work
ii Motor function and overload relay trips
iii Motor function but only partially functional control circuit
Methods of detecting damage
Among the known methods necessary to detect damage are as follows
1 Turn off the electricity at the main switch (main switch) in order to avoid any danger during the
work carried out to detect damage
2 Check all the protective gear that controls the motor control main circuit
11 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
3 Make sure the damage function control circuit
4 Check the control circuit according to the schematic circuit diagram of the motor control
5 Check the operation of the control circuit
Note
Use wiring that has been installed on the SYSTEM OF MOTOR CONTROL BOARD by Forward
Reverse control circuit for Star Delta to test and look for damage
SELF-ASSESSMENT QUESTIONS
1 (a) Explain what is meant by the term lsquoback emfrsquo in a motor
(b) Outline the basic differences between series shunt and compound wound dc motors
2 (a) With the aid of diagrams explain how the speed of series shunt and compound-wound motors
may be controlled
(b) A 440V dc shunt-wound motor has a field resistance of 200R and an armature resistance of 06 R
When its speed is 20 rev d second the current drawn from the supply is 122A Calculate its back
emf at this speed If the speed were decreased to 19 revssecond the field flux remaining unchanged
calculate the new back emf and the new armature current
3 A load of 64 kW at 240 V is supplied from the terminals of a shunt-wound dc generator The field
resistance is 180 A Calculate the armature current
4 (a) Explain with the aid of a diagram how a rotating magnetic field may be
(b) What is meant by lsquosynchronous speedrsquo
Calculate the synchronous obtained speed of a 12 pole motor if the supply frequency is 50Hz
5 (a) Explain the action of a synchronous motor
(b) What methods are available to start a synchronous motor Explain with diagrams
6 (a) Explain the action of a cage induction motor
(b) What is meant by the term lsquosliprsquo
Calculate the percentage slip of a six pole induction motor running at 162 revssecond from a 50 Hz
supply
7 Describe with sketches three different ways of starting a single-phase induction motor
12 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
8 Explain with the aid of a sketch the action of a three-phase DOL starter
What are dashpots used for How are remote start and stop buttons connected
9 A I0 kW 240V 50Hz single-phase cage rotor induction motor is 85efficient and has a PF of 068
lagging Calculate the motor current and the value of capacitor required to raise the PF to 093
lagging
10 Calculate the torque developed by an 18 kW four-pole induction motor run at 35 slip from a
50Hz supply
APPENDIX 1
13 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 11
14 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 111
Attachment Reference
httpswwwtlc-directcoukBook621htm
httpwwwstgovmyindexphpms
15 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 2 WIRING SYSTEM OF SINGLE PHASE LIGHTING CIRCUIT Introduction
Objectives
1 Identify component and the specification
2 Wire component according to the schematic diagram
3 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Wiring bay Perforated metal 180 cm x 180 cm 1
2 Cut out fuse 63 A 240 V 1
3 Neutral link 1
4 Single pole one way switch cw
switch box
5A 240Vac 4
5 single pole two way switch cw
switch box
5A 240Vac 2
6 RCCB In = 40 A Tripping current
100mA240 Vac 50 Hz
1
7 Main switch 32 A 240V 1
8 kWatthour meter 40 A 240 Vac 1
9 Single pole MCB 6A 240 Vac 1
10 Self tapping Wood screw As required
11 DIN rail 35 mm width As required
32 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
12 PVC trunking 50 mm x 50 mm As required
13 Terminal blocks 5 A As required
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
1 One way switch to control one lamp
2 One way switch to control two lamps
3 Two of two way switch to control one lamp
4 Two of single pole two way switch and one of an intermediate switch to control one
lamp
5 One unit of ceiling fan and fan regulator to be controlled by one way switch
4 Test the functionality of completed project
LESSON 3ndash WIRING SYSTEM OF SINGLE PHASE POWER CIRCUIT Introduction
33 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
34 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify types of component and its specification
2 Wire component according to the schematic diagram given
3 Test the functionality of the circuit dead circuit test life circuit test
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board Perforated Metal 1
2 kWh meter 240 V 40 A 1
3 Socket outlet 13A 240Vac 4
4 RCCB 40A Trip Amps
30mA240 Vac
1
5 3 pin socket 240Vac 13A 4
6 Single pole MCB 20A 240 V 2
7 DOL starter 1 kW 240Vac 2
8 1 phase induction motor 2Hp 240 Vac 1
9 Cooker control unit 4kW 240Vac 1
10 Water heater point 4kW 240 Vac 1
11 DIN rail 35 mm As required
12 PVC casing 20mm As required
13 Flexible wires 05 mm As required
14 Terminal block 10 A As required
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Wire two unit of 13 A socket outlet in radial circuit
3 Wire four units of 13 A socket outlet in ring circuit
4 Wire one unit DOL starter for air-conditioner point
5 Wire one unit of cooker control unit point
6 Wire one unit of water heater point
7 Test the functionality of each component by using mmeter or power supply whichever
applicable
8 Wire component according to circuit diagram
9 Test the functionality of completed project dead circuit test life circuit test
Note
35 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Ensure that the correct rating of protection device and size of wire used
LESSON 4ndash CONDUIT BENDING AND TRUNKING FABRICATION TECHNIQUE
Common fitting used in an industrial wiring
Cutting and threading the condute
36 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
37 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
38 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify conduit fitting and the specification
2 Measure and Cut steel conduit according to specified dimension
3 Bend and fabricate conduit at 45 90 according to layout diagram
4 Wire component according to the schematic diagram
5 Test the functionality of the circuit
39 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Conduit Bender Oslash 19 mm ( frac34 ldquo) 1
2 Measuring Tape 3 metre 1
3 Hacksaw frame and blade 30cm 1
4 Conduit cutter 1
5 Pipe Vise 1
6 Pipe Wrench 1
7 Ratchet Dies 20 mm 1
8 Metal trunking 50 mm x 50 mm 1
9 GI conduit 20mm 1
10 End box 20 mm 1
11 Flexible wires 05 mm As required
12 Connectors 5 A As required
13 Single core PVC ins Cable 25 mm 2 As required
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Wire two unit of 13 A socket outlet in radial circuit
3 Wire four unit of 13 A socket outlet in ring circuit
4 Wire one unit DOL starter for air-conditioner point
5 Wire one unit of cooker control unit point
6 Wire one unit of water heater point
7 Test the functionality of each component by using multimeter or power supply whichever
applicable
8 Wire component according to circuit diagram
9 Test the functionality of completed project
Note
Ensure that the rating of protection device and size of wire
K prior to 31 March
2004 (BS 7671)
(formerly)
bare conductor
sleeved at terminations (formerly)
40 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 5 ndashWIRING SYSTEM OF 1 Oslash LIGHTING AND POWER CIRCUIT
POWER CIRCUITSa Radial circuits
Radial circuits are arranged in the same way as item 1 above in lighting layouts in that each socket
outlet is supplied via the previous one
Points to note
1 The number of socket outlets complying with BS 1363 is unlimited for a floor area of up to 50m 2 if
the circuit protection is a 30 A or 32 A cartridge fuse or circuit breaker the cable being 4 mm PVC
copper or 25 mm2 mineral insulated (mi)
2 The number of socket outlets is unlimited for a floor area up to 20 m 2 with any type of circuit
protection of 20 A using 25 mm2 PVC copper cable or 15 mm2 mi
3 The total number of fused spurs is unlimited
b ring final circuits
These circuits are the same as radial circuits except that the final socket outlet is wired back to the
supply position In effect any outlet is supplied from two directions (Fig 152)
Points to note
1 Every twin-socket outlet counts as two single-socket outlets
2 The number of non-fused spurs must not exceed the total number of points on the ring Fig 158
shows seven points on the ring and five spurs
3 The fuse rating of a fused spur box must not exceed 13 A and the current rating of all points supplied
by the fused spur must not exceed 13 A
4 Non-fused spurs must supply no more than one single or one double socket on the ring Fig 158
shows seven points on the ring and five spurs rating of all points supplied by the fused spur must not
exceed 13 A or one stationary appliance
CapacityMain conductor size
copper (mm2)
Earth conductor
size (mm2)
Circuit breaker
capacity (A)
Up to 600 W 15 15 6
600ndash1200 W 1525 15 10
1200ndash1800 W 254 25 16
41 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Ring circuit
(floor area 100 m2)25 15 3032
A2 radial circuit
(floor area 75 m2)40 25 3032
A3 radial circuit
(floor area 50 m2)25 15 20
Air conditioner (15 tonne) 60 60 3032
Cooker 60 60 3032
Water heater 40 40 20
Objectives
1 Identify component and the specification
2 Wire component according to the schematic diagram
3 Test the functionality of the circuit
42 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board Perforated 1
2 Cut out fuse and neutral link 60A 240V 1each
3 kWh meter 240V 40A 1
4 Switched Socket outlet 13A 240Vac 4
5 Single pole two way switch cw switch
box
5A 240Vac 2
6 RCCB ELCB 63 A Tripping current 100mA
415 Vac
1
7 3 pin plug 240Vac 13A 4
8 Single pole MCB 20 A 2
9 Single pole MCB 6A 1
10 Single pole MCB 20A 2
11 DOL starter 240Vac 2
12 1 phase induction motor 2hp 240 Vac 1
13 Self tapping Wood screw As required
14 DIN rail Stainless steel allum35 mm As required
15 PVC pipe 20mm dia As required
16 End box 20 mm dia 4
17 Flexible wires 05 mm 2 As required
18 Connectors 5 A As required
Procedures
43 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
4 Test the functionality of completed project
LESSON 6 ndash WIRING SYSTEM OF 3 Oslash DISTRIBUTION BOARD
Introduction
44 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
45 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
46 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
47 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
48 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify each component and the specification
2 Wire component according to the schematic diagram given
3 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting Board 450 x 600 mm Perforated metal 1
2 5 pin round socket and plug 415V ac 32A 1
3 Cut out fuse 60 A 3
4 Neutral link 1
5 kWatt hour meter 415V 60A 1
6 ELCB RCCB 3P+N In=63A415 Vac I trip= 300mA 1
7 ELCB RCCB 3P+N In=63A415 Vac I trip= 30mA 1
8 Single pole MCB 6A 240 V 3
9 Single pole MCB 20A 240 V 3
10 DOL starter 20 A 240Vac 2
11 Socket outlet 15 A 240 Vac 1
12 Switched Socket outlet 13 A 240 Vac 3
13 Led indicating light 5A 240 Vac 3
14 Single pole 4 gang 1 way switch 5A 240 Vac 2
15 Single pole 2 way switch 5A 240 Vac 2
16 1 phase induction motor 1 kW 240Vac 1
17 Metal trunking 30 mm x30 mm As required
18 Self tapping Wood screw 4 mm x 20 mm As required
19 DIN rail 25 mm x 1mm
20 GI steel rigid conduit 20mm As required
21 Flexible conduit 20mm As required
22 End box 20 mm 4
23 Flexible wires 05 mm 2 As required
24 Single core PVC insulated wire 15 mm 2 As required
25 Single core PVC insulated wires 25 mm 2 As required
26 Terminal block 10 A As required
Procedures
49 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify each components and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
4 Test the functionality of completed project
1 dead circuit test
2 life circuit
Note Proper earthing should be made
50 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 7 ndash WIRING SYSTEM OF THREE PHASE LIGHTING AND POWER CIRCUIT
51 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
52 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify component and the specification
2 Wire component according to the schematic diagram
3 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting bay Board Perforated metal 180 cm x 180 cm 1
2 k Watt hour meter 415V 60A 1
3 MCCB 415V 60A
4 ELCB RCCB In=60A415 Vac I trip=30mA 1
5 5 pin round Socket and
plug
415Vac 32A 4
6 Single pole MCB 6A 1
7 Triple pole MCB 20A 2
8 Triple pole Main switch 60A 1
9 DOL starter 240Vac 2
10 3 phase induction motor 2hp 415 Vac 1
11 1 phase induction motor 1
12 Metal trunking 30 mm x30 mm As required
13 Self tapping Wood screw 4 mm x 20 mm As required
14 DIN rail 25 mm x 1mm
15 GI steel rigid conduit 20mm As required
16 Flexible conduit 20mm As required
17 End box 20 mm 4
18 Flexible wires 05 mm As required
19 Connectors 10 A As required
Procedures
1 Identify each components and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
4 Test the functionality of completed project
1 dead circuit 2 life circuit test
5 Record the current drawn by the load as connected in star and delta
Note Proper earthing should be made
53 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 8 INSPECTION AND TESTING OF ELECTRICAL INSTALLATION
On completion of a wiring installation a number of tests on the installation have to be conducted to
ascertain that the wiring circuits and connected appliances are safe for use Prior to carrying out the
tests an inspection has to be done The results of the inspectionsupervision and test have to be
presented in Form G (as in Appendix IV) and Form H (as in Appendix V)
To have the test certification as in Form H the following tests shall be conducted
i Continuity Test
ii Insulation Resistance Test
iii Polarity Test
iv Earth Electrode Resistance test and
v Residual Current Device Test
1 Continuity Test
There are 3 main types of continuity tests for the final circuits-
i Protection Conductor Continuity Test
ii Final Ring Circuit Conductor Continuity Test
iii Live and Neutral Conductor Continuity Test
a) Protection Conductor Continuity Test
bull To ascertain that all protection conductors are connected in the correct and effective manner
bull Test equipment ndash Multimeter (Ohm range) or Ohm meter
54 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
bull Test Method
1 1048766 Ensure that the main switch RCD and MCB are open circuited (switched off) and all loads
are disconnected
2 1048766 Connected the test leads as in the Figure 81 The meter reading shall be less than 1 Ω
55 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Final Ring Circuit Conductor Continuity Test
bull To ensure that all conductors around the ring circuit have continuity
bull Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
bull Test Method
1 1048766 Disconnect both the supply source live conductors from the MCB the neutral conductor
from the neutral terminals and the earth conductor from the earth terminal in the distribution
fuse box
2 1048766 Connect the test leads as in the Figure 82 (EE)
3 1048766 Repeat the procedure for (L-L) and (N-N)
4 1048766 The meter reading value shall be less than 1 ohm
56 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Live and Neutral Conductor Continuity Test
a To ensure that each conductor in the circuit has continuity
b Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
2 Test Method
1 1048766 Switch off the Main switch RCD and MCB
2 1048766 Disconnect all loads
3 1048766 Switch on all switches in the circuit
4 1048766 Disconnect the fusesfinal circuit breakers and close the circuit
5 1048766 Carry out the test as shown in Figure 83
6 1048766 The meter reading value shall be less than 1Ω
57 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
58 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
CONTINUITY TEST
Insulation Resistance Test
i Ensure that there is no leakage current between phase conductors phase and neutral conductors and
phase conductor and earth
ii Test the strength of the cable insulation
iii Test Equipment ndash Insulation Resistance Tester operating voltage is 250VDC or 500VDC
iv Test Method
1 1048766 Switch off main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
59 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
4 1048766 Carry out test as in the Table below
5 1048766 Meter reading value shall be less than 1 Megaohm
60 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
61 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Insulation resitance test
62 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
INSULATION RESISTANCE TEST BETWEEN CONDUCTORS AND OPPOSITE POLARITY
Polarity Testi Ensure that each fuse or single pole control and protection device is connected only in the phase
conductor
ii Intermediate contact of Edison screw lamp holder is connected to the phase conductor
iii Ensure that phase neutral and earth conductors at socket outlets are connected at the correct
terminals
iv Test Equipment ndash Multimeter (Ohm range) or Ohm meter
v Test Method
1 1048766 Switch off Main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in Figure 85
63 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
5 1048766 Test switches and single phase control devices at the phase conductors
6 1048766 Test socket outlet connection sources
7 1048766 Test Edison screw lamp holder connections
8 1048766 Meter reading value shall be less than 1 Ω
64 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Polarity test
65 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Earth Electrode Resistance Testi To test the earth electrode resistance
ii To ascertain the suitability of the location of the electrode
iii To ensure that the electrode is not buried within the resistance area of another electrode
iv Test equipment ndash Earth Resistance Tester
v Test method -
1 1048766 Terminal rsquoErsquo is connected to the electrode to be tested (green conductor)
2 1048766 Terminal lsquoPrsquo is connected to the potential spike (yellow conductor) at a distance of 10
meters from the earth electrode
3 1048766 Terminal lsquoCrsquo is connected to the current spike (red conductor) at a distance of 20 meters
from the earth electrode
Earth Electrode Resistance Measurement Method (Figure 86)
This test must be repeated at least three times to ensure that the reading is not affected by interacting
earthing regions
i Record the first reading (Z1) Example Z1 = 10 Ω
ii Move the voltage spike to a distance of 6 meters from the original position Record the second
reading (Z2 ) Example Z2 = 10 Ω
iii Move the voltage spike to a distance of 6 meters from the original position Record the third
reading (Z3) Example Z3 = 10 Ω
66 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Residual Current Device Testi Ensure that the residual current device (RCD) trips within the set time on the occurrence of current
leakage to earth
ii Test Equipment ndash RCD Tester RCCB Tester
iii Test Method 1
1 1048766 Use the Trip Test Button
2 1048766 Press the trip button found on the RCD to determine if it trips or otherwise This test would
not be able to determine the sensitivity of the RCD nor the time taken for it to trip
iv Test Method 2
i 1048766 Use a RCD Tester
ii This equipment is equipped with a 13A plug which can be connected to a 13A socket outlet
Select the RCD sensitivity to be the same as the sensitivity of the RCD to be tested to
determine if the RCD can trip The time to trip shall not exceed 40 mS
iii 1048766 Test method ndash
a) Position the selection switch in accordance with the sensitivity of the RCD used
Example 100 mA 01 A
b) Position the operations switch to lsquoNo Triprsquo (frac12 Rated mA = 50) connect the 3 pin plug to
the 13A socket outlet
67 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
c) Switch on the 13A socket outlet ndash ensure that the P-N and P-E lights light up
This shows that the polarity is correct (Note if both the lights as above do not light up the test cannot
be continued)
d) Press the test button ndash the reading shows less than 200 mS and simultaneously the lsquotestrsquo light lights
up and the P-N and P-E lights do not light up At that instant the RCD will not trip
e) Move the selection switch to 180o (+ve wave) ndash repeat steps (d) and (e) Move the operations
switch to lsquoTriprsquo (Rated mA = 100)
g) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200mS
h) Move the selection switch to 0o (-ve wave)
i) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
j) The above test is repeated until a near correct reading is obtained
k) Record the test results
l) Change the operations switch to lsquoFast Triprsquo and press the test button ndash RCD will trip within a
time not exceeding 40 millisecond
m) Repeat a number of times at 0o or 180o
On completion of a wiring installation a number of tests on the installation have to be conducted to
ascertain that the wiring circuits and connected appliances are safe for use Prior to carrying out the
tests an inspection has to be done the following tests shall be conducted
i Continuity Test
ii Insulation Resistance Test
iii Polarity Test
iv Earth Electrode Resistance test and
v Residual Current Device Test
821 Continuity Test
There are 3 main types of continuity tests for the final circuits-
i Protection Conductor Continuity Test
ii Final Ring Circuit Conductor Continuity Test
68 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
iii Live and Neutral Conductor Continuity Test
a) Protection Conductor Continuity Test
bull To ascertain that all protection conductors are connected in the correct and effective manner
bull Test equipment ndash Multimeter (Ohm range) or Ohm meter
bull Test Method
1 1048766 Ensure that the main switch RCD and MCB are open circuited (switched off) and all loads are
disconnected
2 1048766 Connected the test leads as in the Figure 81
3 1048766 The meter reading shall be less than 1 Ω
Final Ring Circuit Conductor Continuity Test
bull To ensure that all conductors around the ring circuit have continuity
bull Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
bull Test Method
1 1048766 Disconnect both the supply source live conductors from the MCB the neutral conductor
from the neutral terminals and the earth conductor from the earth terminal in the distribution
fuse box
2 1048766 Connect the test leads as in the Figure 82 (EE)
3 1048766 Repeat the procedure for (L-L) and (N-N)
4 1048766 The meter reading value shall be less than 1 ohm Figure 82 - Final Ring Circuit Conductor
Continuity Test Ohm Meter
Disconnect both the supply source cables from mcbfuse
Take readings at earth conductors of both sources and note resistance readings
Live and Neutral Conductor Continuity Test
1 To ensure that each conductor in the circuit has continuity
2 Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
3 Test Method
1 1048766 Switch off the Main switch RCD and MCB
2 1048766 Disconnect all loads
3 1048766 Switch on all switches in the circuit
4 1048766 Disconnect the fusesfinal circuit breakers and close the circuit
5 1048766 Carry out the test as shown in Figure 83
6 1048766 The meter reading value shall be less than 1 ohm Figure 83 - Live and Neutral
Conductor Continuity Test Ohm Meter
Insulation Resistance Test
69 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
i Ensure that there is no leakage current between phase conductors phase and neutral conductors and
phase conductor and earth
ii Test the strength of the cable insulation
iii Test Equipment ndash Insulation Resistance Tester Operating voltage is 250VDC or 500VDC
iv Test Method
1 1048766 Switch off main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in the Table below
5 1048766 Meter reading value shall be less than 1 Megaohm
Polarity Test
i Ensure that each fuse or single pole control and protection device is connected only in the phase
conductor
ii Intermediate contact of Edison screw lamp holder is connected to the phase conductor
iii Ensure that phase neutral and earth conductors at socket outlets are connected at the correct
terminals
iv Test Equipment ndash Multimeter (Ohm range) or Ohm meter
v Test Method
1 1048766 Switch off Main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in Figure 85
5 1048766 Test switches and single phase control devices at the phase conductors
6 1048766 Test socket outlet connection sources
7 1048766 Test Edison screw lamp holder connections
8 1048766 Meter reading value shall be less than 1 Ω
Earth Electrode Resistance Test
i To test the earth electrode resistance
70 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
ii To ascertain the suitability of the location of the electrode
iii To ensure that the electrode is not buried within the resistance area of another electrode
iv Test equipment ndash Earth Resistance Tester
v Test method -
1 1048766 Terminal rsquoErsquo is connected to the electrode to be tested (green conductor)
2 1048766 Terminal lsquoPrsquo is connected to the potential spike (yellow conductor) at a distance of 10
meters from the earth electrode
3 1048766 Terminal lsquoCrsquo is connected to the current spike (red conductor) at a distance of 20 meters
from the earth electrode E P C Electrode 10 meter 10 meter
Figure 86 ndash Earth Electrode Resistance Measurement Test Equipment
Earth Electrode Resistance Measurement Method (Figure 86)
This test must be repeated at least three times to ensure that the reading is not affected by interacting
earthing regions
i Record the first reading (Z1) Example Z1 = 10 Ω
ii Move the voltage spike to a distance of 6 meters from the original position Record the second
reading (Z2) Example Z2 = 10 Ω
iii Move the voltage spike to a distance of 6 meters from the original position Record the third
reading (Z3)
Example Z3 = 10 Ω
Residual Current Device Test
71 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
i Ensure that the residual current device (RCD) trips within the set time on the occurrence of current
leakage to earth
ii Test Equipment ndash RCD Tester RCCB Tester
iii Test Method 1
1 1048766 Use the Trip Test Button
2 1048766 Press the trip button found on the RCD to determine if it trips or otherwise This test would
not be able to determine the sensitivity of the RCD nor the time taken for it to trip
iv Test Method 2
1048766 Use a RCD Tester
This equipment is equipped with a 13A plug which can be connected to a 13A socket outlet Select the
RCD sensitivity to be the same as the sensitivity of the RCD to be tested to determine if the RCD can
trip The time to trip shall not exceed 40 mS
1048766 Test method ndash
a) Position the selection switch in accordance with the sensitivity of the RCD used
Example 100 mA 01 A
b) Position the operations switch to lsquoNo Triprsquo (frac12 Rated mA = 50) connect the 3 pin plug to
the 13A socket outlet
c) Switch on the 13A socket outlet ndash ensure that the P-N and P-E lights light up This shows that
the polarity is correct (Note if both the lights as above do not light up the test cannot be
continued)
d) Press the test button ndash the reading shows less than 200 millisecond and simultaneously the
lsquotestrsquo light lights up and the P-N and P-E lights do not light up At that instant the RCD will
not trip
e) Move the selection switch to 180o (+ve wave) ndash repeat steps (d) and (e) = 100)
f) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
g) Move the selection switch to 0o (-ve wave)
h) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
i) The above test is repeated until a near correct reading is obtained
j) Record the test results
k) Change the operations switch to lsquoFast Triprsquo and press the test button ndash RCD will trip within a
time not exceeding 40 mS
l) Repeat a number of times at 0o or 180o
72 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 9 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (DC)
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
73 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Start stop button 240Vac 5A 2
9 Filament lamp (Bulb ) 240Vac 40W 3
10 Overload Relay 415V 20A 3
11 Three phase induction motor 5 hp 3
12 Single phase step down transformer 2500VA 1
13 Single core PVC insulated Cable 1mm 2 As required
14 Single core PVC insulated Cable 25mm 2 As required
15 DIN rail 35 mm As required
16 PVC type Cable tray 50 mm x 50 mm As required
17 Cable ties 4 ldquo As required
18 Flexible wires 05 mm As required
19 PVC Connectors 5 A amp 20 A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the schematic
diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a optional exercise
i Simple DOL starter
ii Forward reverse DOL starter
iii Forward Reverse Dahlander motor
iv Three motors operated in sequence by DOL starter operated by manual push
button or time delay relay
74 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
a One loop per-cycle
b Continuous operation in a loop
c optional circuit design to represent the same task
v Only one out of three motors to be operated at a time (quiz)
4 Test the functionality of completed project
LESSON 10 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (AC)
75 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 1
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Lamp point 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
76 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
11 Overload Relay 415V 20A 3
12 Three phase induction
motor
5 hp 3
13 Single core PVC insulated
Cable
1mm 2 As required
14 Single core PVC insulated
Cable
25mm 2 As required
15 DIN rail 35 mm As required
16 PVC type Cable tray 50 mm x 50 mm As required
17 Cable ties 4 ldquo As required
18 Flexible wires 05 mm As required
19 PVC Connectors 5 A amp 20 A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the
schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram optional exercise
4 Simple DOL starter
5 Forward reverse DOL starter
6 Test the functionality of completed project
77 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 1
78 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
cm
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Indicating light 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
11 Overload Relay 415V 20A 3
12 Three phase induction motor 5 hp 3
13 Single phase step down
transformer
2500VA 1
14 Single core PVC insulated
Cable
1mm 2 As required
15 Single core PVC insulated
Cable
25mm 2 As required
16 DIN rail 35 mm As required
17 PVC type Cable tray 50 mm x 50 mm As required
18 Cable ties 4 ldquo As required
19 Flexible wires 05 mm As required
20 PVC Connectors 5 A amp 20 A 240 V As required
21 Single pole MCB 6A 240 V 1
22 Single pole MCB 2A 240 V 1
23 Triple pole MCB 20A 415 V 1
24 Mounting board 30 cm x 40 cm x 3
cm
1
25 Relay cw 11 pin socket 10 A 240 Vac 2
26 Time delay relay 10 A 240 Vac 3
27 Triple pole Contactor 20A 240Vac 3
28 Batten type Lamp holder 240Vac 10 A 3
29 Start stop button 240Vac 10A 2
30 Indicating light (Bulb ) 240Vac 25W 3
31 Overload Relay 415V 20A 1
32 Three phase dahlander type
induction motor
5 hp 1
33 Single phase step down
transformer
24024Vac
2500VA
1
79 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
34 Single core PVC insulated
Cable
1mm 2 As required
35 Single core PVC insulated
Cable
25mm 2 As required
36 DIN rail 35 mm As required
37 PVC type Cable tray 50 mm x 50 mm As required
38 Cable ties 4 ldquo As required
39 Flexible wires 075 mm As required
40 PVC Connectors 5 A amp 20 A 240 V As required
41 Terminal block 20A 240Vac As required
Procedures
5 Identify each component according to specification and quantity required from the schematic
diagram attached
6 Test the functionality of each component by using multi-meter or power supply whichever
applicable
7 Wire component according to circuit diagram
8 Three motors operated in sequence by DOL starter operated by manual push button or time
delay relay
a One loop per-cycle
b Continuous operation in a loop
c optional circuit design to represent the same task
d Only one out of three motors to be operated at a time (quiz)
9 Test the functionality of completed project
80 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
BASIC DESIGN INDUSTRIAL MOTOR CONTROL (SEQUENCE CONTROL)
THREE PHASE INDUCTION MOTOR OPERATED IN SEQUENCE BY DIRECT ON LINE
STARTER
LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
81 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
82 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Lcd lamp indicator 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
11 Overload Relay 415V 20A 3
12 Three phase induction motor 5 hp 3
13 Single phase step down transformer 2500VA 1
14 Single core PVC insulated Cable 1mm 2 As required
15 Single core PVC insulated Cable 25mm 2 As required
16 DIN rail 35 mm As required
17 PVC type Cable tray 50 mm x 50 mm As required
18 Cable ties 4 ldquo As required
19 Flexible wires 1 mm Oslash As required
20 PVC Terminal block 10A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the schematic
diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a optional exercise
i Forward Reverse dahlander motor
4 Test the functionality of completed project
83 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
THREE PHASE DAHLANDER TYPE INDUCTION MOTOR OPERATED FORWARD AND
REVERSE OPERATION BY DIRECT ON LINE STARTER
84 ndash 99EASYTECH ENTERPRISE
LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
Introduction
If a motors windings are connected in the star configuration any two phases will be in series across
the supply and hence the line current will be smaller(by 577) than if the windings were connected in
the delta arrangement
Hence larger-type motors with heavy starting currents are first connected in star and then when the
starting currents fall in delta This of course means that all six of the ends of the windings must be
brought to terminations outside the casing (Fig 833)
EZTECH
EZTECH ELECTRICAL INSTALLATION GUIDE
The automatic version of this starter incorporates a timing relay which automatically changes the
connections from star to delta Figs 834 and 835 show the wiring and schematic diagrams for a star
delta starter
Objectives
1 Identify component and the specification
2 Design forward reverse star delta starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
2 ndash 99EASYTECH ENTERPRISE
REV -C
LEGENDMCCB Moulded Case Circuit BreakerTOR Thermal Over Load RelayFOW-C Mains Forward ContactorREV-C Mains Reverse ContactorDC Delta ContactorSC Star ContactorS-SW Mains Selector Switch
SC
V2
W2
U2
DC
V1
W1
U1
TOR
TOR
FOW-C
30A MCCB
TOR
MAIN CIRCUIT FORWARD REVERSE STAR DELTA
RYBN S
-SW
3 PHASEINDUCTION MOTOR
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Relay 10 A 240V 3
5 Triple pole Contactor
6 cw NO NC auxiliary contact
240Vac 20 A 4
7 Overload Relay 415 V 1
8 LED indicator 240vac 5 A 4
9 Start stop button 240Vac 5A 2
10 DIN rail 35 mm As required
11 Flexible wires 1 mm As required
12 Single core PVC insulated
wire
25 mm As required
13 Terminal block 20 A As required
14 Squirrel cage motor 5kW 1
15 5 pin plug and socket 415V 20A 1
16 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
3 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
a Manual star delta
b Manual Forward reverse star delta starter
c Automatic star delta starter
d Automatic Forward reverse star delta starter
4 Test the functionality of completed project
4 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
Objectives
1 Identify component and the specification
2 Design auto transformer starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
5 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Autotransformer starter is used to start a 3 phase induction motor that has a rating between 10 to 15 hp
6 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Autotransformer set 10Kw 415 V 50 Hz 1
5 Triple pole Contactor 240Vac 4
6 Batten type Lamp holder 240 Vac 105 A 4
7 Start stop button 240Vac 10A 4
8 Filament lamp (Bulb ) 240Vac 40W 4
9 DIN rail 35 mm As required
10 Flexible wires 1 mm As required
7 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
11 Single core PVC insulated
wire
25 mm As required
12 Terminal block 20 A As required
13 Squirrel cage motor 10kW 1
14 5 pin plug and socket 415V 20A 1
15 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a open transient autotransformer starter
b close transient autotransformer starter
c Forward reverse autotransformer starter
4 Test the functionality of completed project
8 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
Objectives
1 Identify component and the specification
2 Design rotor resistance starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
9 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Rotor Resistor set 10kW 1
5 Triple pole Contactor 240Vac 20A 4
6 Indicating light 240vac 5 A 4
7 Start stop push button 240Vac 5A 4
8 DIN rail 35 mm As required
9 Flexible wires 1 mm 2 As required
10 Single core PVC insulated wire 25 mm 2 As required
11 Terminal block 20 A As required
12 Slip Ring motor 10kW 1
13 5 pin round 3 phase socket 415V 20A 1
14 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
10 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
4 Test the functionality of completed project
a Dead circuit test b Life circuit test
5 Measure starting and running Amps
LESSON 16
TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
An installation in general will suffer damage
Damage usually occurs on the electric motor control as follows
1 Damage to the main circuit
2 Damage to the control circuit
The cause of the damage
i Overcurrent overload short circuit
ii Leakage current to ground
iii Equipment malfunction
iv The main control circuit
a Trip of main circuit protection devices fire
b Defect of motor terminal such as short circuit fire loose
v The control circuit is not functioning -
a contactor relay relay time overload relay does not work damaged burned
b Loose cable connection disconnected
Detecting and Repairing Damage
Examples of damage are as follows
i Motor does not work
ii Motor function and overload relay trips
iii Motor function but only partially functional control circuit
Methods of detecting damage
Among the known methods necessary to detect damage are as follows
1 Turn off the electricity at the main switch (main switch) in order to avoid any danger during the
work carried out to detect damage
2 Check all the protective gear that controls the motor control main circuit
11 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
3 Make sure the damage function control circuit
4 Check the control circuit according to the schematic circuit diagram of the motor control
5 Check the operation of the control circuit
Note
Use wiring that has been installed on the SYSTEM OF MOTOR CONTROL BOARD by Forward
Reverse control circuit for Star Delta to test and look for damage
SELF-ASSESSMENT QUESTIONS
1 (a) Explain what is meant by the term lsquoback emfrsquo in a motor
(b) Outline the basic differences between series shunt and compound wound dc motors
2 (a) With the aid of diagrams explain how the speed of series shunt and compound-wound motors
may be controlled
(b) A 440V dc shunt-wound motor has a field resistance of 200R and an armature resistance of 06 R
When its speed is 20 rev d second the current drawn from the supply is 122A Calculate its back
emf at this speed If the speed were decreased to 19 revssecond the field flux remaining unchanged
calculate the new back emf and the new armature current
3 A load of 64 kW at 240 V is supplied from the terminals of a shunt-wound dc generator The field
resistance is 180 A Calculate the armature current
4 (a) Explain with the aid of a diagram how a rotating magnetic field may be
(b) What is meant by lsquosynchronous speedrsquo
Calculate the synchronous obtained speed of a 12 pole motor if the supply frequency is 50Hz
5 (a) Explain the action of a synchronous motor
(b) What methods are available to start a synchronous motor Explain with diagrams
6 (a) Explain the action of a cage induction motor
(b) What is meant by the term lsquosliprsquo
Calculate the percentage slip of a six pole induction motor running at 162 revssecond from a 50 Hz
supply
7 Describe with sketches three different ways of starting a single-phase induction motor
12 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
8 Explain with the aid of a sketch the action of a three-phase DOL starter
What are dashpots used for How are remote start and stop buttons connected
9 A I0 kW 240V 50Hz single-phase cage rotor induction motor is 85efficient and has a PF of 068
lagging Calculate the motor current and the value of capacitor required to raise the PF to 093
lagging
10 Calculate the torque developed by an 18 kW four-pole induction motor run at 35 slip from a
50Hz supply
APPENDIX 1
13 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 11
14 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 111
Attachment Reference
httpswwwtlc-directcoukBook621htm
httpwwwstgovmyindexphpms
15 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
12 PVC trunking 50 mm x 50 mm As required
13 Terminal blocks 5 A As required
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
1 One way switch to control one lamp
2 One way switch to control two lamps
3 Two of two way switch to control one lamp
4 Two of single pole two way switch and one of an intermediate switch to control one
lamp
5 One unit of ceiling fan and fan regulator to be controlled by one way switch
4 Test the functionality of completed project
LESSON 3ndash WIRING SYSTEM OF SINGLE PHASE POWER CIRCUIT Introduction
33 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
34 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify types of component and its specification
2 Wire component according to the schematic diagram given
3 Test the functionality of the circuit dead circuit test life circuit test
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board Perforated Metal 1
2 kWh meter 240 V 40 A 1
3 Socket outlet 13A 240Vac 4
4 RCCB 40A Trip Amps
30mA240 Vac
1
5 3 pin socket 240Vac 13A 4
6 Single pole MCB 20A 240 V 2
7 DOL starter 1 kW 240Vac 2
8 1 phase induction motor 2Hp 240 Vac 1
9 Cooker control unit 4kW 240Vac 1
10 Water heater point 4kW 240 Vac 1
11 DIN rail 35 mm As required
12 PVC casing 20mm As required
13 Flexible wires 05 mm As required
14 Terminal block 10 A As required
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Wire two unit of 13 A socket outlet in radial circuit
3 Wire four units of 13 A socket outlet in ring circuit
4 Wire one unit DOL starter for air-conditioner point
5 Wire one unit of cooker control unit point
6 Wire one unit of water heater point
7 Test the functionality of each component by using mmeter or power supply whichever
applicable
8 Wire component according to circuit diagram
9 Test the functionality of completed project dead circuit test life circuit test
Note
35 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Ensure that the correct rating of protection device and size of wire used
LESSON 4ndash CONDUIT BENDING AND TRUNKING FABRICATION TECHNIQUE
Common fitting used in an industrial wiring
Cutting and threading the condute
36 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
37 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
38 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify conduit fitting and the specification
2 Measure and Cut steel conduit according to specified dimension
3 Bend and fabricate conduit at 45 90 according to layout diagram
4 Wire component according to the schematic diagram
5 Test the functionality of the circuit
39 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Conduit Bender Oslash 19 mm ( frac34 ldquo) 1
2 Measuring Tape 3 metre 1
3 Hacksaw frame and blade 30cm 1
4 Conduit cutter 1
5 Pipe Vise 1
6 Pipe Wrench 1
7 Ratchet Dies 20 mm 1
8 Metal trunking 50 mm x 50 mm 1
9 GI conduit 20mm 1
10 End box 20 mm 1
11 Flexible wires 05 mm As required
12 Connectors 5 A As required
13 Single core PVC ins Cable 25 mm 2 As required
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Wire two unit of 13 A socket outlet in radial circuit
3 Wire four unit of 13 A socket outlet in ring circuit
4 Wire one unit DOL starter for air-conditioner point
5 Wire one unit of cooker control unit point
6 Wire one unit of water heater point
7 Test the functionality of each component by using multimeter or power supply whichever
applicable
8 Wire component according to circuit diagram
9 Test the functionality of completed project
Note
Ensure that the rating of protection device and size of wire
K prior to 31 March
2004 (BS 7671)
(formerly)
bare conductor
sleeved at terminations (formerly)
40 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 5 ndashWIRING SYSTEM OF 1 Oslash LIGHTING AND POWER CIRCUIT
POWER CIRCUITSa Radial circuits
Radial circuits are arranged in the same way as item 1 above in lighting layouts in that each socket
outlet is supplied via the previous one
Points to note
1 The number of socket outlets complying with BS 1363 is unlimited for a floor area of up to 50m 2 if
the circuit protection is a 30 A or 32 A cartridge fuse or circuit breaker the cable being 4 mm PVC
copper or 25 mm2 mineral insulated (mi)
2 The number of socket outlets is unlimited for a floor area up to 20 m 2 with any type of circuit
protection of 20 A using 25 mm2 PVC copper cable or 15 mm2 mi
3 The total number of fused spurs is unlimited
b ring final circuits
These circuits are the same as radial circuits except that the final socket outlet is wired back to the
supply position In effect any outlet is supplied from two directions (Fig 152)
Points to note
1 Every twin-socket outlet counts as two single-socket outlets
2 The number of non-fused spurs must not exceed the total number of points on the ring Fig 158
shows seven points on the ring and five spurs
3 The fuse rating of a fused spur box must not exceed 13 A and the current rating of all points supplied
by the fused spur must not exceed 13 A
4 Non-fused spurs must supply no more than one single or one double socket on the ring Fig 158
shows seven points on the ring and five spurs rating of all points supplied by the fused spur must not
exceed 13 A or one stationary appliance
CapacityMain conductor size
copper (mm2)
Earth conductor
size (mm2)
Circuit breaker
capacity (A)
Up to 600 W 15 15 6
600ndash1200 W 1525 15 10
1200ndash1800 W 254 25 16
41 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Ring circuit
(floor area 100 m2)25 15 3032
A2 radial circuit
(floor area 75 m2)40 25 3032
A3 radial circuit
(floor area 50 m2)25 15 20
Air conditioner (15 tonne) 60 60 3032
Cooker 60 60 3032
Water heater 40 40 20
Objectives
1 Identify component and the specification
2 Wire component according to the schematic diagram
3 Test the functionality of the circuit
42 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board Perforated 1
2 Cut out fuse and neutral link 60A 240V 1each
3 kWh meter 240V 40A 1
4 Switched Socket outlet 13A 240Vac 4
5 Single pole two way switch cw switch
box
5A 240Vac 2
6 RCCB ELCB 63 A Tripping current 100mA
415 Vac
1
7 3 pin plug 240Vac 13A 4
8 Single pole MCB 20 A 2
9 Single pole MCB 6A 1
10 Single pole MCB 20A 2
11 DOL starter 240Vac 2
12 1 phase induction motor 2hp 240 Vac 1
13 Self tapping Wood screw As required
14 DIN rail Stainless steel allum35 mm As required
15 PVC pipe 20mm dia As required
16 End box 20 mm dia 4
17 Flexible wires 05 mm 2 As required
18 Connectors 5 A As required
Procedures
43 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
4 Test the functionality of completed project
LESSON 6 ndash WIRING SYSTEM OF 3 Oslash DISTRIBUTION BOARD
Introduction
44 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
45 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
46 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
47 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
48 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify each component and the specification
2 Wire component according to the schematic diagram given
3 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting Board 450 x 600 mm Perforated metal 1
2 5 pin round socket and plug 415V ac 32A 1
3 Cut out fuse 60 A 3
4 Neutral link 1
5 kWatt hour meter 415V 60A 1
6 ELCB RCCB 3P+N In=63A415 Vac I trip= 300mA 1
7 ELCB RCCB 3P+N In=63A415 Vac I trip= 30mA 1
8 Single pole MCB 6A 240 V 3
9 Single pole MCB 20A 240 V 3
10 DOL starter 20 A 240Vac 2
11 Socket outlet 15 A 240 Vac 1
12 Switched Socket outlet 13 A 240 Vac 3
13 Led indicating light 5A 240 Vac 3
14 Single pole 4 gang 1 way switch 5A 240 Vac 2
15 Single pole 2 way switch 5A 240 Vac 2
16 1 phase induction motor 1 kW 240Vac 1
17 Metal trunking 30 mm x30 mm As required
18 Self tapping Wood screw 4 mm x 20 mm As required
19 DIN rail 25 mm x 1mm
20 GI steel rigid conduit 20mm As required
21 Flexible conduit 20mm As required
22 End box 20 mm 4
23 Flexible wires 05 mm 2 As required
24 Single core PVC insulated wire 15 mm 2 As required
25 Single core PVC insulated wires 25 mm 2 As required
26 Terminal block 10 A As required
Procedures
49 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify each components and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
4 Test the functionality of completed project
1 dead circuit test
2 life circuit
Note Proper earthing should be made
50 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 7 ndash WIRING SYSTEM OF THREE PHASE LIGHTING AND POWER CIRCUIT
51 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
52 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify component and the specification
2 Wire component according to the schematic diagram
3 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting bay Board Perforated metal 180 cm x 180 cm 1
2 k Watt hour meter 415V 60A 1
3 MCCB 415V 60A
4 ELCB RCCB In=60A415 Vac I trip=30mA 1
5 5 pin round Socket and
plug
415Vac 32A 4
6 Single pole MCB 6A 1
7 Triple pole MCB 20A 2
8 Triple pole Main switch 60A 1
9 DOL starter 240Vac 2
10 3 phase induction motor 2hp 415 Vac 1
11 1 phase induction motor 1
12 Metal trunking 30 mm x30 mm As required
13 Self tapping Wood screw 4 mm x 20 mm As required
14 DIN rail 25 mm x 1mm
15 GI steel rigid conduit 20mm As required
16 Flexible conduit 20mm As required
17 End box 20 mm 4
18 Flexible wires 05 mm As required
19 Connectors 10 A As required
Procedures
1 Identify each components and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
4 Test the functionality of completed project
1 dead circuit 2 life circuit test
5 Record the current drawn by the load as connected in star and delta
Note Proper earthing should be made
53 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 8 INSPECTION AND TESTING OF ELECTRICAL INSTALLATION
On completion of a wiring installation a number of tests on the installation have to be conducted to
ascertain that the wiring circuits and connected appliances are safe for use Prior to carrying out the
tests an inspection has to be done The results of the inspectionsupervision and test have to be
presented in Form G (as in Appendix IV) and Form H (as in Appendix V)
To have the test certification as in Form H the following tests shall be conducted
i Continuity Test
ii Insulation Resistance Test
iii Polarity Test
iv Earth Electrode Resistance test and
v Residual Current Device Test
1 Continuity Test
There are 3 main types of continuity tests for the final circuits-
i Protection Conductor Continuity Test
ii Final Ring Circuit Conductor Continuity Test
iii Live and Neutral Conductor Continuity Test
a) Protection Conductor Continuity Test
bull To ascertain that all protection conductors are connected in the correct and effective manner
bull Test equipment ndash Multimeter (Ohm range) or Ohm meter
54 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
bull Test Method
1 1048766 Ensure that the main switch RCD and MCB are open circuited (switched off) and all loads
are disconnected
2 1048766 Connected the test leads as in the Figure 81 The meter reading shall be less than 1 Ω
55 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Final Ring Circuit Conductor Continuity Test
bull To ensure that all conductors around the ring circuit have continuity
bull Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
bull Test Method
1 1048766 Disconnect both the supply source live conductors from the MCB the neutral conductor
from the neutral terminals and the earth conductor from the earth terminal in the distribution
fuse box
2 1048766 Connect the test leads as in the Figure 82 (EE)
3 1048766 Repeat the procedure for (L-L) and (N-N)
4 1048766 The meter reading value shall be less than 1 ohm
56 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Live and Neutral Conductor Continuity Test
a To ensure that each conductor in the circuit has continuity
b Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
2 Test Method
1 1048766 Switch off the Main switch RCD and MCB
2 1048766 Disconnect all loads
3 1048766 Switch on all switches in the circuit
4 1048766 Disconnect the fusesfinal circuit breakers and close the circuit
5 1048766 Carry out the test as shown in Figure 83
6 1048766 The meter reading value shall be less than 1Ω
57 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
58 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
CONTINUITY TEST
Insulation Resistance Test
i Ensure that there is no leakage current between phase conductors phase and neutral conductors and
phase conductor and earth
ii Test the strength of the cable insulation
iii Test Equipment ndash Insulation Resistance Tester operating voltage is 250VDC or 500VDC
iv Test Method
1 1048766 Switch off main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
59 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
4 1048766 Carry out test as in the Table below
5 1048766 Meter reading value shall be less than 1 Megaohm
60 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
61 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Insulation resitance test
62 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
INSULATION RESISTANCE TEST BETWEEN CONDUCTORS AND OPPOSITE POLARITY
Polarity Testi Ensure that each fuse or single pole control and protection device is connected only in the phase
conductor
ii Intermediate contact of Edison screw lamp holder is connected to the phase conductor
iii Ensure that phase neutral and earth conductors at socket outlets are connected at the correct
terminals
iv Test Equipment ndash Multimeter (Ohm range) or Ohm meter
v Test Method
1 1048766 Switch off Main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in Figure 85
63 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
5 1048766 Test switches and single phase control devices at the phase conductors
6 1048766 Test socket outlet connection sources
7 1048766 Test Edison screw lamp holder connections
8 1048766 Meter reading value shall be less than 1 Ω
64 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Polarity test
65 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Earth Electrode Resistance Testi To test the earth electrode resistance
ii To ascertain the suitability of the location of the electrode
iii To ensure that the electrode is not buried within the resistance area of another electrode
iv Test equipment ndash Earth Resistance Tester
v Test method -
1 1048766 Terminal rsquoErsquo is connected to the electrode to be tested (green conductor)
2 1048766 Terminal lsquoPrsquo is connected to the potential spike (yellow conductor) at a distance of 10
meters from the earth electrode
3 1048766 Terminal lsquoCrsquo is connected to the current spike (red conductor) at a distance of 20 meters
from the earth electrode
Earth Electrode Resistance Measurement Method (Figure 86)
This test must be repeated at least three times to ensure that the reading is not affected by interacting
earthing regions
i Record the first reading (Z1) Example Z1 = 10 Ω
ii Move the voltage spike to a distance of 6 meters from the original position Record the second
reading (Z2 ) Example Z2 = 10 Ω
iii Move the voltage spike to a distance of 6 meters from the original position Record the third
reading (Z3) Example Z3 = 10 Ω
66 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Residual Current Device Testi Ensure that the residual current device (RCD) trips within the set time on the occurrence of current
leakage to earth
ii Test Equipment ndash RCD Tester RCCB Tester
iii Test Method 1
1 1048766 Use the Trip Test Button
2 1048766 Press the trip button found on the RCD to determine if it trips or otherwise This test would
not be able to determine the sensitivity of the RCD nor the time taken for it to trip
iv Test Method 2
i 1048766 Use a RCD Tester
ii This equipment is equipped with a 13A plug which can be connected to a 13A socket outlet
Select the RCD sensitivity to be the same as the sensitivity of the RCD to be tested to
determine if the RCD can trip The time to trip shall not exceed 40 mS
iii 1048766 Test method ndash
a) Position the selection switch in accordance with the sensitivity of the RCD used
Example 100 mA 01 A
b) Position the operations switch to lsquoNo Triprsquo (frac12 Rated mA = 50) connect the 3 pin plug to
the 13A socket outlet
67 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
c) Switch on the 13A socket outlet ndash ensure that the P-N and P-E lights light up
This shows that the polarity is correct (Note if both the lights as above do not light up the test cannot
be continued)
d) Press the test button ndash the reading shows less than 200 mS and simultaneously the lsquotestrsquo light lights
up and the P-N and P-E lights do not light up At that instant the RCD will not trip
e) Move the selection switch to 180o (+ve wave) ndash repeat steps (d) and (e) Move the operations
switch to lsquoTriprsquo (Rated mA = 100)
g) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200mS
h) Move the selection switch to 0o (-ve wave)
i) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
j) The above test is repeated until a near correct reading is obtained
k) Record the test results
l) Change the operations switch to lsquoFast Triprsquo and press the test button ndash RCD will trip within a
time not exceeding 40 millisecond
m) Repeat a number of times at 0o or 180o
On completion of a wiring installation a number of tests on the installation have to be conducted to
ascertain that the wiring circuits and connected appliances are safe for use Prior to carrying out the
tests an inspection has to be done the following tests shall be conducted
i Continuity Test
ii Insulation Resistance Test
iii Polarity Test
iv Earth Electrode Resistance test and
v Residual Current Device Test
821 Continuity Test
There are 3 main types of continuity tests for the final circuits-
i Protection Conductor Continuity Test
ii Final Ring Circuit Conductor Continuity Test
68 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
iii Live and Neutral Conductor Continuity Test
a) Protection Conductor Continuity Test
bull To ascertain that all protection conductors are connected in the correct and effective manner
bull Test equipment ndash Multimeter (Ohm range) or Ohm meter
bull Test Method
1 1048766 Ensure that the main switch RCD and MCB are open circuited (switched off) and all loads are
disconnected
2 1048766 Connected the test leads as in the Figure 81
3 1048766 The meter reading shall be less than 1 Ω
Final Ring Circuit Conductor Continuity Test
bull To ensure that all conductors around the ring circuit have continuity
bull Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
bull Test Method
1 1048766 Disconnect both the supply source live conductors from the MCB the neutral conductor
from the neutral terminals and the earth conductor from the earth terminal in the distribution
fuse box
2 1048766 Connect the test leads as in the Figure 82 (EE)
3 1048766 Repeat the procedure for (L-L) and (N-N)
4 1048766 The meter reading value shall be less than 1 ohm Figure 82 - Final Ring Circuit Conductor
Continuity Test Ohm Meter
Disconnect both the supply source cables from mcbfuse
Take readings at earth conductors of both sources and note resistance readings
Live and Neutral Conductor Continuity Test
1 To ensure that each conductor in the circuit has continuity
2 Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
3 Test Method
1 1048766 Switch off the Main switch RCD and MCB
2 1048766 Disconnect all loads
3 1048766 Switch on all switches in the circuit
4 1048766 Disconnect the fusesfinal circuit breakers and close the circuit
5 1048766 Carry out the test as shown in Figure 83
6 1048766 The meter reading value shall be less than 1 ohm Figure 83 - Live and Neutral
Conductor Continuity Test Ohm Meter
Insulation Resistance Test
69 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
i Ensure that there is no leakage current between phase conductors phase and neutral conductors and
phase conductor and earth
ii Test the strength of the cable insulation
iii Test Equipment ndash Insulation Resistance Tester Operating voltage is 250VDC or 500VDC
iv Test Method
1 1048766 Switch off main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in the Table below
5 1048766 Meter reading value shall be less than 1 Megaohm
Polarity Test
i Ensure that each fuse or single pole control and protection device is connected only in the phase
conductor
ii Intermediate contact of Edison screw lamp holder is connected to the phase conductor
iii Ensure that phase neutral and earth conductors at socket outlets are connected at the correct
terminals
iv Test Equipment ndash Multimeter (Ohm range) or Ohm meter
v Test Method
1 1048766 Switch off Main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in Figure 85
5 1048766 Test switches and single phase control devices at the phase conductors
6 1048766 Test socket outlet connection sources
7 1048766 Test Edison screw lamp holder connections
8 1048766 Meter reading value shall be less than 1 Ω
Earth Electrode Resistance Test
i To test the earth electrode resistance
70 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
ii To ascertain the suitability of the location of the electrode
iii To ensure that the electrode is not buried within the resistance area of another electrode
iv Test equipment ndash Earth Resistance Tester
v Test method -
1 1048766 Terminal rsquoErsquo is connected to the electrode to be tested (green conductor)
2 1048766 Terminal lsquoPrsquo is connected to the potential spike (yellow conductor) at a distance of 10
meters from the earth electrode
3 1048766 Terminal lsquoCrsquo is connected to the current spike (red conductor) at a distance of 20 meters
from the earth electrode E P C Electrode 10 meter 10 meter
Figure 86 ndash Earth Electrode Resistance Measurement Test Equipment
Earth Electrode Resistance Measurement Method (Figure 86)
This test must be repeated at least three times to ensure that the reading is not affected by interacting
earthing regions
i Record the first reading (Z1) Example Z1 = 10 Ω
ii Move the voltage spike to a distance of 6 meters from the original position Record the second
reading (Z2) Example Z2 = 10 Ω
iii Move the voltage spike to a distance of 6 meters from the original position Record the third
reading (Z3)
Example Z3 = 10 Ω
Residual Current Device Test
71 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
i Ensure that the residual current device (RCD) trips within the set time on the occurrence of current
leakage to earth
ii Test Equipment ndash RCD Tester RCCB Tester
iii Test Method 1
1 1048766 Use the Trip Test Button
2 1048766 Press the trip button found on the RCD to determine if it trips or otherwise This test would
not be able to determine the sensitivity of the RCD nor the time taken for it to trip
iv Test Method 2
1048766 Use a RCD Tester
This equipment is equipped with a 13A plug which can be connected to a 13A socket outlet Select the
RCD sensitivity to be the same as the sensitivity of the RCD to be tested to determine if the RCD can
trip The time to trip shall not exceed 40 mS
1048766 Test method ndash
a) Position the selection switch in accordance with the sensitivity of the RCD used
Example 100 mA 01 A
b) Position the operations switch to lsquoNo Triprsquo (frac12 Rated mA = 50) connect the 3 pin plug to
the 13A socket outlet
c) Switch on the 13A socket outlet ndash ensure that the P-N and P-E lights light up This shows that
the polarity is correct (Note if both the lights as above do not light up the test cannot be
continued)
d) Press the test button ndash the reading shows less than 200 millisecond and simultaneously the
lsquotestrsquo light lights up and the P-N and P-E lights do not light up At that instant the RCD will
not trip
e) Move the selection switch to 180o (+ve wave) ndash repeat steps (d) and (e) = 100)
f) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
g) Move the selection switch to 0o (-ve wave)
h) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
i) The above test is repeated until a near correct reading is obtained
j) Record the test results
k) Change the operations switch to lsquoFast Triprsquo and press the test button ndash RCD will trip within a
time not exceeding 40 mS
l) Repeat a number of times at 0o or 180o
72 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 9 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (DC)
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
73 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Start stop button 240Vac 5A 2
9 Filament lamp (Bulb ) 240Vac 40W 3
10 Overload Relay 415V 20A 3
11 Three phase induction motor 5 hp 3
12 Single phase step down transformer 2500VA 1
13 Single core PVC insulated Cable 1mm 2 As required
14 Single core PVC insulated Cable 25mm 2 As required
15 DIN rail 35 mm As required
16 PVC type Cable tray 50 mm x 50 mm As required
17 Cable ties 4 ldquo As required
18 Flexible wires 05 mm As required
19 PVC Connectors 5 A amp 20 A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the schematic
diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a optional exercise
i Simple DOL starter
ii Forward reverse DOL starter
iii Forward Reverse Dahlander motor
iv Three motors operated in sequence by DOL starter operated by manual push
button or time delay relay
74 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
a One loop per-cycle
b Continuous operation in a loop
c optional circuit design to represent the same task
v Only one out of three motors to be operated at a time (quiz)
4 Test the functionality of completed project
LESSON 10 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (AC)
75 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 1
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Lamp point 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
76 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
11 Overload Relay 415V 20A 3
12 Three phase induction
motor
5 hp 3
13 Single core PVC insulated
Cable
1mm 2 As required
14 Single core PVC insulated
Cable
25mm 2 As required
15 DIN rail 35 mm As required
16 PVC type Cable tray 50 mm x 50 mm As required
17 Cable ties 4 ldquo As required
18 Flexible wires 05 mm As required
19 PVC Connectors 5 A amp 20 A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the
schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram optional exercise
4 Simple DOL starter
5 Forward reverse DOL starter
6 Test the functionality of completed project
77 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 1
78 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
cm
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Indicating light 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
11 Overload Relay 415V 20A 3
12 Three phase induction motor 5 hp 3
13 Single phase step down
transformer
2500VA 1
14 Single core PVC insulated
Cable
1mm 2 As required
15 Single core PVC insulated
Cable
25mm 2 As required
16 DIN rail 35 mm As required
17 PVC type Cable tray 50 mm x 50 mm As required
18 Cable ties 4 ldquo As required
19 Flexible wires 05 mm As required
20 PVC Connectors 5 A amp 20 A 240 V As required
21 Single pole MCB 6A 240 V 1
22 Single pole MCB 2A 240 V 1
23 Triple pole MCB 20A 415 V 1
24 Mounting board 30 cm x 40 cm x 3
cm
1
25 Relay cw 11 pin socket 10 A 240 Vac 2
26 Time delay relay 10 A 240 Vac 3
27 Triple pole Contactor 20A 240Vac 3
28 Batten type Lamp holder 240Vac 10 A 3
29 Start stop button 240Vac 10A 2
30 Indicating light (Bulb ) 240Vac 25W 3
31 Overload Relay 415V 20A 1
32 Three phase dahlander type
induction motor
5 hp 1
33 Single phase step down
transformer
24024Vac
2500VA
1
79 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
34 Single core PVC insulated
Cable
1mm 2 As required
35 Single core PVC insulated
Cable
25mm 2 As required
36 DIN rail 35 mm As required
37 PVC type Cable tray 50 mm x 50 mm As required
38 Cable ties 4 ldquo As required
39 Flexible wires 075 mm As required
40 PVC Connectors 5 A amp 20 A 240 V As required
41 Terminal block 20A 240Vac As required
Procedures
5 Identify each component according to specification and quantity required from the schematic
diagram attached
6 Test the functionality of each component by using multi-meter or power supply whichever
applicable
7 Wire component according to circuit diagram
8 Three motors operated in sequence by DOL starter operated by manual push button or time
delay relay
a One loop per-cycle
b Continuous operation in a loop
c optional circuit design to represent the same task
d Only one out of three motors to be operated at a time (quiz)
9 Test the functionality of completed project
80 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
BASIC DESIGN INDUSTRIAL MOTOR CONTROL (SEQUENCE CONTROL)
THREE PHASE INDUCTION MOTOR OPERATED IN SEQUENCE BY DIRECT ON LINE
STARTER
LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
81 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
82 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Lcd lamp indicator 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
11 Overload Relay 415V 20A 3
12 Three phase induction motor 5 hp 3
13 Single phase step down transformer 2500VA 1
14 Single core PVC insulated Cable 1mm 2 As required
15 Single core PVC insulated Cable 25mm 2 As required
16 DIN rail 35 mm As required
17 PVC type Cable tray 50 mm x 50 mm As required
18 Cable ties 4 ldquo As required
19 Flexible wires 1 mm Oslash As required
20 PVC Terminal block 10A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the schematic
diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a optional exercise
i Forward Reverse dahlander motor
4 Test the functionality of completed project
83 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
THREE PHASE DAHLANDER TYPE INDUCTION MOTOR OPERATED FORWARD AND
REVERSE OPERATION BY DIRECT ON LINE STARTER
84 ndash 99EASYTECH ENTERPRISE
LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
Introduction
If a motors windings are connected in the star configuration any two phases will be in series across
the supply and hence the line current will be smaller(by 577) than if the windings were connected in
the delta arrangement
Hence larger-type motors with heavy starting currents are first connected in star and then when the
starting currents fall in delta This of course means that all six of the ends of the windings must be
brought to terminations outside the casing (Fig 833)
EZTECH
EZTECH ELECTRICAL INSTALLATION GUIDE
The automatic version of this starter incorporates a timing relay which automatically changes the
connections from star to delta Figs 834 and 835 show the wiring and schematic diagrams for a star
delta starter
Objectives
1 Identify component and the specification
2 Design forward reverse star delta starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
2 ndash 99EASYTECH ENTERPRISE
REV -C
LEGENDMCCB Moulded Case Circuit BreakerTOR Thermal Over Load RelayFOW-C Mains Forward ContactorREV-C Mains Reverse ContactorDC Delta ContactorSC Star ContactorS-SW Mains Selector Switch
SC
V2
W2
U2
DC
V1
W1
U1
TOR
TOR
FOW-C
30A MCCB
TOR
MAIN CIRCUIT FORWARD REVERSE STAR DELTA
RYBN S
-SW
3 PHASEINDUCTION MOTOR
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Relay 10 A 240V 3
5 Triple pole Contactor
6 cw NO NC auxiliary contact
240Vac 20 A 4
7 Overload Relay 415 V 1
8 LED indicator 240vac 5 A 4
9 Start stop button 240Vac 5A 2
10 DIN rail 35 mm As required
11 Flexible wires 1 mm As required
12 Single core PVC insulated
wire
25 mm As required
13 Terminal block 20 A As required
14 Squirrel cage motor 5kW 1
15 5 pin plug and socket 415V 20A 1
16 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
3 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
a Manual star delta
b Manual Forward reverse star delta starter
c Automatic star delta starter
d Automatic Forward reverse star delta starter
4 Test the functionality of completed project
4 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
Objectives
1 Identify component and the specification
2 Design auto transformer starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
5 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Autotransformer starter is used to start a 3 phase induction motor that has a rating between 10 to 15 hp
6 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Autotransformer set 10Kw 415 V 50 Hz 1
5 Triple pole Contactor 240Vac 4
6 Batten type Lamp holder 240 Vac 105 A 4
7 Start stop button 240Vac 10A 4
8 Filament lamp (Bulb ) 240Vac 40W 4
9 DIN rail 35 mm As required
10 Flexible wires 1 mm As required
7 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
11 Single core PVC insulated
wire
25 mm As required
12 Terminal block 20 A As required
13 Squirrel cage motor 10kW 1
14 5 pin plug and socket 415V 20A 1
15 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a open transient autotransformer starter
b close transient autotransformer starter
c Forward reverse autotransformer starter
4 Test the functionality of completed project
8 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
Objectives
1 Identify component and the specification
2 Design rotor resistance starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
9 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Rotor Resistor set 10kW 1
5 Triple pole Contactor 240Vac 20A 4
6 Indicating light 240vac 5 A 4
7 Start stop push button 240Vac 5A 4
8 DIN rail 35 mm As required
9 Flexible wires 1 mm 2 As required
10 Single core PVC insulated wire 25 mm 2 As required
11 Terminal block 20 A As required
12 Slip Ring motor 10kW 1
13 5 pin round 3 phase socket 415V 20A 1
14 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
10 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
4 Test the functionality of completed project
a Dead circuit test b Life circuit test
5 Measure starting and running Amps
LESSON 16
TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
An installation in general will suffer damage
Damage usually occurs on the electric motor control as follows
1 Damage to the main circuit
2 Damage to the control circuit
The cause of the damage
i Overcurrent overload short circuit
ii Leakage current to ground
iii Equipment malfunction
iv The main control circuit
a Trip of main circuit protection devices fire
b Defect of motor terminal such as short circuit fire loose
v The control circuit is not functioning -
a contactor relay relay time overload relay does not work damaged burned
b Loose cable connection disconnected
Detecting and Repairing Damage
Examples of damage are as follows
i Motor does not work
ii Motor function and overload relay trips
iii Motor function but only partially functional control circuit
Methods of detecting damage
Among the known methods necessary to detect damage are as follows
1 Turn off the electricity at the main switch (main switch) in order to avoid any danger during the
work carried out to detect damage
2 Check all the protective gear that controls the motor control main circuit
11 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
3 Make sure the damage function control circuit
4 Check the control circuit according to the schematic circuit diagram of the motor control
5 Check the operation of the control circuit
Note
Use wiring that has been installed on the SYSTEM OF MOTOR CONTROL BOARD by Forward
Reverse control circuit for Star Delta to test and look for damage
SELF-ASSESSMENT QUESTIONS
1 (a) Explain what is meant by the term lsquoback emfrsquo in a motor
(b) Outline the basic differences between series shunt and compound wound dc motors
2 (a) With the aid of diagrams explain how the speed of series shunt and compound-wound motors
may be controlled
(b) A 440V dc shunt-wound motor has a field resistance of 200R and an armature resistance of 06 R
When its speed is 20 rev d second the current drawn from the supply is 122A Calculate its back
emf at this speed If the speed were decreased to 19 revssecond the field flux remaining unchanged
calculate the new back emf and the new armature current
3 A load of 64 kW at 240 V is supplied from the terminals of a shunt-wound dc generator The field
resistance is 180 A Calculate the armature current
4 (a) Explain with the aid of a diagram how a rotating magnetic field may be
(b) What is meant by lsquosynchronous speedrsquo
Calculate the synchronous obtained speed of a 12 pole motor if the supply frequency is 50Hz
5 (a) Explain the action of a synchronous motor
(b) What methods are available to start a synchronous motor Explain with diagrams
6 (a) Explain the action of a cage induction motor
(b) What is meant by the term lsquosliprsquo
Calculate the percentage slip of a six pole induction motor running at 162 revssecond from a 50 Hz
supply
7 Describe with sketches three different ways of starting a single-phase induction motor
12 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
8 Explain with the aid of a sketch the action of a three-phase DOL starter
What are dashpots used for How are remote start and stop buttons connected
9 A I0 kW 240V 50Hz single-phase cage rotor induction motor is 85efficient and has a PF of 068
lagging Calculate the motor current and the value of capacitor required to raise the PF to 093
lagging
10 Calculate the torque developed by an 18 kW four-pole induction motor run at 35 slip from a
50Hz supply
APPENDIX 1
13 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 11
14 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 111
Attachment Reference
httpswwwtlc-directcoukBook621htm
httpwwwstgovmyindexphpms
15 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
34 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify types of component and its specification
2 Wire component according to the schematic diagram given
3 Test the functionality of the circuit dead circuit test life circuit test
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board Perforated Metal 1
2 kWh meter 240 V 40 A 1
3 Socket outlet 13A 240Vac 4
4 RCCB 40A Trip Amps
30mA240 Vac
1
5 3 pin socket 240Vac 13A 4
6 Single pole MCB 20A 240 V 2
7 DOL starter 1 kW 240Vac 2
8 1 phase induction motor 2Hp 240 Vac 1
9 Cooker control unit 4kW 240Vac 1
10 Water heater point 4kW 240 Vac 1
11 DIN rail 35 mm As required
12 PVC casing 20mm As required
13 Flexible wires 05 mm As required
14 Terminal block 10 A As required
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Wire two unit of 13 A socket outlet in radial circuit
3 Wire four units of 13 A socket outlet in ring circuit
4 Wire one unit DOL starter for air-conditioner point
5 Wire one unit of cooker control unit point
6 Wire one unit of water heater point
7 Test the functionality of each component by using mmeter or power supply whichever
applicable
8 Wire component according to circuit diagram
9 Test the functionality of completed project dead circuit test life circuit test
Note
35 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Ensure that the correct rating of protection device and size of wire used
LESSON 4ndash CONDUIT BENDING AND TRUNKING FABRICATION TECHNIQUE
Common fitting used in an industrial wiring
Cutting and threading the condute
36 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
37 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
38 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify conduit fitting and the specification
2 Measure and Cut steel conduit according to specified dimension
3 Bend and fabricate conduit at 45 90 according to layout diagram
4 Wire component according to the schematic diagram
5 Test the functionality of the circuit
39 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Conduit Bender Oslash 19 mm ( frac34 ldquo) 1
2 Measuring Tape 3 metre 1
3 Hacksaw frame and blade 30cm 1
4 Conduit cutter 1
5 Pipe Vise 1
6 Pipe Wrench 1
7 Ratchet Dies 20 mm 1
8 Metal trunking 50 mm x 50 mm 1
9 GI conduit 20mm 1
10 End box 20 mm 1
11 Flexible wires 05 mm As required
12 Connectors 5 A As required
13 Single core PVC ins Cable 25 mm 2 As required
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Wire two unit of 13 A socket outlet in radial circuit
3 Wire four unit of 13 A socket outlet in ring circuit
4 Wire one unit DOL starter for air-conditioner point
5 Wire one unit of cooker control unit point
6 Wire one unit of water heater point
7 Test the functionality of each component by using multimeter or power supply whichever
applicable
8 Wire component according to circuit diagram
9 Test the functionality of completed project
Note
Ensure that the rating of protection device and size of wire
K prior to 31 March
2004 (BS 7671)
(formerly)
bare conductor
sleeved at terminations (formerly)
40 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 5 ndashWIRING SYSTEM OF 1 Oslash LIGHTING AND POWER CIRCUIT
POWER CIRCUITSa Radial circuits
Radial circuits are arranged in the same way as item 1 above in lighting layouts in that each socket
outlet is supplied via the previous one
Points to note
1 The number of socket outlets complying with BS 1363 is unlimited for a floor area of up to 50m 2 if
the circuit protection is a 30 A or 32 A cartridge fuse or circuit breaker the cable being 4 mm PVC
copper or 25 mm2 mineral insulated (mi)
2 The number of socket outlets is unlimited for a floor area up to 20 m 2 with any type of circuit
protection of 20 A using 25 mm2 PVC copper cable or 15 mm2 mi
3 The total number of fused spurs is unlimited
b ring final circuits
These circuits are the same as radial circuits except that the final socket outlet is wired back to the
supply position In effect any outlet is supplied from two directions (Fig 152)
Points to note
1 Every twin-socket outlet counts as two single-socket outlets
2 The number of non-fused spurs must not exceed the total number of points on the ring Fig 158
shows seven points on the ring and five spurs
3 The fuse rating of a fused spur box must not exceed 13 A and the current rating of all points supplied
by the fused spur must not exceed 13 A
4 Non-fused spurs must supply no more than one single or one double socket on the ring Fig 158
shows seven points on the ring and five spurs rating of all points supplied by the fused spur must not
exceed 13 A or one stationary appliance
CapacityMain conductor size
copper (mm2)
Earth conductor
size (mm2)
Circuit breaker
capacity (A)
Up to 600 W 15 15 6
600ndash1200 W 1525 15 10
1200ndash1800 W 254 25 16
41 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Ring circuit
(floor area 100 m2)25 15 3032
A2 radial circuit
(floor area 75 m2)40 25 3032
A3 radial circuit
(floor area 50 m2)25 15 20
Air conditioner (15 tonne) 60 60 3032
Cooker 60 60 3032
Water heater 40 40 20
Objectives
1 Identify component and the specification
2 Wire component according to the schematic diagram
3 Test the functionality of the circuit
42 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board Perforated 1
2 Cut out fuse and neutral link 60A 240V 1each
3 kWh meter 240V 40A 1
4 Switched Socket outlet 13A 240Vac 4
5 Single pole two way switch cw switch
box
5A 240Vac 2
6 RCCB ELCB 63 A Tripping current 100mA
415 Vac
1
7 3 pin plug 240Vac 13A 4
8 Single pole MCB 20 A 2
9 Single pole MCB 6A 1
10 Single pole MCB 20A 2
11 DOL starter 240Vac 2
12 1 phase induction motor 2hp 240 Vac 1
13 Self tapping Wood screw As required
14 DIN rail Stainless steel allum35 mm As required
15 PVC pipe 20mm dia As required
16 End box 20 mm dia 4
17 Flexible wires 05 mm 2 As required
18 Connectors 5 A As required
Procedures
43 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
4 Test the functionality of completed project
LESSON 6 ndash WIRING SYSTEM OF 3 Oslash DISTRIBUTION BOARD
Introduction
44 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
45 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
46 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
47 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
48 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify each component and the specification
2 Wire component according to the schematic diagram given
3 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting Board 450 x 600 mm Perforated metal 1
2 5 pin round socket and plug 415V ac 32A 1
3 Cut out fuse 60 A 3
4 Neutral link 1
5 kWatt hour meter 415V 60A 1
6 ELCB RCCB 3P+N In=63A415 Vac I trip= 300mA 1
7 ELCB RCCB 3P+N In=63A415 Vac I trip= 30mA 1
8 Single pole MCB 6A 240 V 3
9 Single pole MCB 20A 240 V 3
10 DOL starter 20 A 240Vac 2
11 Socket outlet 15 A 240 Vac 1
12 Switched Socket outlet 13 A 240 Vac 3
13 Led indicating light 5A 240 Vac 3
14 Single pole 4 gang 1 way switch 5A 240 Vac 2
15 Single pole 2 way switch 5A 240 Vac 2
16 1 phase induction motor 1 kW 240Vac 1
17 Metal trunking 30 mm x30 mm As required
18 Self tapping Wood screw 4 mm x 20 mm As required
19 DIN rail 25 mm x 1mm
20 GI steel rigid conduit 20mm As required
21 Flexible conduit 20mm As required
22 End box 20 mm 4
23 Flexible wires 05 mm 2 As required
24 Single core PVC insulated wire 15 mm 2 As required
25 Single core PVC insulated wires 25 mm 2 As required
26 Terminal block 10 A As required
Procedures
49 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify each components and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
4 Test the functionality of completed project
1 dead circuit test
2 life circuit
Note Proper earthing should be made
50 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 7 ndash WIRING SYSTEM OF THREE PHASE LIGHTING AND POWER CIRCUIT
51 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
52 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify component and the specification
2 Wire component according to the schematic diagram
3 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting bay Board Perforated metal 180 cm x 180 cm 1
2 k Watt hour meter 415V 60A 1
3 MCCB 415V 60A
4 ELCB RCCB In=60A415 Vac I trip=30mA 1
5 5 pin round Socket and
plug
415Vac 32A 4
6 Single pole MCB 6A 1
7 Triple pole MCB 20A 2
8 Triple pole Main switch 60A 1
9 DOL starter 240Vac 2
10 3 phase induction motor 2hp 415 Vac 1
11 1 phase induction motor 1
12 Metal trunking 30 mm x30 mm As required
13 Self tapping Wood screw 4 mm x 20 mm As required
14 DIN rail 25 mm x 1mm
15 GI steel rigid conduit 20mm As required
16 Flexible conduit 20mm As required
17 End box 20 mm 4
18 Flexible wires 05 mm As required
19 Connectors 10 A As required
Procedures
1 Identify each components and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
4 Test the functionality of completed project
1 dead circuit 2 life circuit test
5 Record the current drawn by the load as connected in star and delta
Note Proper earthing should be made
53 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 8 INSPECTION AND TESTING OF ELECTRICAL INSTALLATION
On completion of a wiring installation a number of tests on the installation have to be conducted to
ascertain that the wiring circuits and connected appliances are safe for use Prior to carrying out the
tests an inspection has to be done The results of the inspectionsupervision and test have to be
presented in Form G (as in Appendix IV) and Form H (as in Appendix V)
To have the test certification as in Form H the following tests shall be conducted
i Continuity Test
ii Insulation Resistance Test
iii Polarity Test
iv Earth Electrode Resistance test and
v Residual Current Device Test
1 Continuity Test
There are 3 main types of continuity tests for the final circuits-
i Protection Conductor Continuity Test
ii Final Ring Circuit Conductor Continuity Test
iii Live and Neutral Conductor Continuity Test
a) Protection Conductor Continuity Test
bull To ascertain that all protection conductors are connected in the correct and effective manner
bull Test equipment ndash Multimeter (Ohm range) or Ohm meter
54 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
bull Test Method
1 1048766 Ensure that the main switch RCD and MCB are open circuited (switched off) and all loads
are disconnected
2 1048766 Connected the test leads as in the Figure 81 The meter reading shall be less than 1 Ω
55 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Final Ring Circuit Conductor Continuity Test
bull To ensure that all conductors around the ring circuit have continuity
bull Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
bull Test Method
1 1048766 Disconnect both the supply source live conductors from the MCB the neutral conductor
from the neutral terminals and the earth conductor from the earth terminal in the distribution
fuse box
2 1048766 Connect the test leads as in the Figure 82 (EE)
3 1048766 Repeat the procedure for (L-L) and (N-N)
4 1048766 The meter reading value shall be less than 1 ohm
56 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Live and Neutral Conductor Continuity Test
a To ensure that each conductor in the circuit has continuity
b Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
2 Test Method
1 1048766 Switch off the Main switch RCD and MCB
2 1048766 Disconnect all loads
3 1048766 Switch on all switches in the circuit
4 1048766 Disconnect the fusesfinal circuit breakers and close the circuit
5 1048766 Carry out the test as shown in Figure 83
6 1048766 The meter reading value shall be less than 1Ω
57 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
58 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
CONTINUITY TEST
Insulation Resistance Test
i Ensure that there is no leakage current between phase conductors phase and neutral conductors and
phase conductor and earth
ii Test the strength of the cable insulation
iii Test Equipment ndash Insulation Resistance Tester operating voltage is 250VDC or 500VDC
iv Test Method
1 1048766 Switch off main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
59 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
4 1048766 Carry out test as in the Table below
5 1048766 Meter reading value shall be less than 1 Megaohm
60 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
61 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Insulation resitance test
62 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
INSULATION RESISTANCE TEST BETWEEN CONDUCTORS AND OPPOSITE POLARITY
Polarity Testi Ensure that each fuse or single pole control and protection device is connected only in the phase
conductor
ii Intermediate contact of Edison screw lamp holder is connected to the phase conductor
iii Ensure that phase neutral and earth conductors at socket outlets are connected at the correct
terminals
iv Test Equipment ndash Multimeter (Ohm range) or Ohm meter
v Test Method
1 1048766 Switch off Main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in Figure 85
63 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
5 1048766 Test switches and single phase control devices at the phase conductors
6 1048766 Test socket outlet connection sources
7 1048766 Test Edison screw lamp holder connections
8 1048766 Meter reading value shall be less than 1 Ω
64 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Polarity test
65 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Earth Electrode Resistance Testi To test the earth electrode resistance
ii To ascertain the suitability of the location of the electrode
iii To ensure that the electrode is not buried within the resistance area of another electrode
iv Test equipment ndash Earth Resistance Tester
v Test method -
1 1048766 Terminal rsquoErsquo is connected to the electrode to be tested (green conductor)
2 1048766 Terminal lsquoPrsquo is connected to the potential spike (yellow conductor) at a distance of 10
meters from the earth electrode
3 1048766 Terminal lsquoCrsquo is connected to the current spike (red conductor) at a distance of 20 meters
from the earth electrode
Earth Electrode Resistance Measurement Method (Figure 86)
This test must be repeated at least three times to ensure that the reading is not affected by interacting
earthing regions
i Record the first reading (Z1) Example Z1 = 10 Ω
ii Move the voltage spike to a distance of 6 meters from the original position Record the second
reading (Z2 ) Example Z2 = 10 Ω
iii Move the voltage spike to a distance of 6 meters from the original position Record the third
reading (Z3) Example Z3 = 10 Ω
66 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Residual Current Device Testi Ensure that the residual current device (RCD) trips within the set time on the occurrence of current
leakage to earth
ii Test Equipment ndash RCD Tester RCCB Tester
iii Test Method 1
1 1048766 Use the Trip Test Button
2 1048766 Press the trip button found on the RCD to determine if it trips or otherwise This test would
not be able to determine the sensitivity of the RCD nor the time taken for it to trip
iv Test Method 2
i 1048766 Use a RCD Tester
ii This equipment is equipped with a 13A plug which can be connected to a 13A socket outlet
Select the RCD sensitivity to be the same as the sensitivity of the RCD to be tested to
determine if the RCD can trip The time to trip shall not exceed 40 mS
iii 1048766 Test method ndash
a) Position the selection switch in accordance with the sensitivity of the RCD used
Example 100 mA 01 A
b) Position the operations switch to lsquoNo Triprsquo (frac12 Rated mA = 50) connect the 3 pin plug to
the 13A socket outlet
67 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
c) Switch on the 13A socket outlet ndash ensure that the P-N and P-E lights light up
This shows that the polarity is correct (Note if both the lights as above do not light up the test cannot
be continued)
d) Press the test button ndash the reading shows less than 200 mS and simultaneously the lsquotestrsquo light lights
up and the P-N and P-E lights do not light up At that instant the RCD will not trip
e) Move the selection switch to 180o (+ve wave) ndash repeat steps (d) and (e) Move the operations
switch to lsquoTriprsquo (Rated mA = 100)
g) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200mS
h) Move the selection switch to 0o (-ve wave)
i) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
j) The above test is repeated until a near correct reading is obtained
k) Record the test results
l) Change the operations switch to lsquoFast Triprsquo and press the test button ndash RCD will trip within a
time not exceeding 40 millisecond
m) Repeat a number of times at 0o or 180o
On completion of a wiring installation a number of tests on the installation have to be conducted to
ascertain that the wiring circuits and connected appliances are safe for use Prior to carrying out the
tests an inspection has to be done the following tests shall be conducted
i Continuity Test
ii Insulation Resistance Test
iii Polarity Test
iv Earth Electrode Resistance test and
v Residual Current Device Test
821 Continuity Test
There are 3 main types of continuity tests for the final circuits-
i Protection Conductor Continuity Test
ii Final Ring Circuit Conductor Continuity Test
68 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
iii Live and Neutral Conductor Continuity Test
a) Protection Conductor Continuity Test
bull To ascertain that all protection conductors are connected in the correct and effective manner
bull Test equipment ndash Multimeter (Ohm range) or Ohm meter
bull Test Method
1 1048766 Ensure that the main switch RCD and MCB are open circuited (switched off) and all loads are
disconnected
2 1048766 Connected the test leads as in the Figure 81
3 1048766 The meter reading shall be less than 1 Ω
Final Ring Circuit Conductor Continuity Test
bull To ensure that all conductors around the ring circuit have continuity
bull Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
bull Test Method
1 1048766 Disconnect both the supply source live conductors from the MCB the neutral conductor
from the neutral terminals and the earth conductor from the earth terminal in the distribution
fuse box
2 1048766 Connect the test leads as in the Figure 82 (EE)
3 1048766 Repeat the procedure for (L-L) and (N-N)
4 1048766 The meter reading value shall be less than 1 ohm Figure 82 - Final Ring Circuit Conductor
Continuity Test Ohm Meter
Disconnect both the supply source cables from mcbfuse
Take readings at earth conductors of both sources and note resistance readings
Live and Neutral Conductor Continuity Test
1 To ensure that each conductor in the circuit has continuity
2 Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
3 Test Method
1 1048766 Switch off the Main switch RCD and MCB
2 1048766 Disconnect all loads
3 1048766 Switch on all switches in the circuit
4 1048766 Disconnect the fusesfinal circuit breakers and close the circuit
5 1048766 Carry out the test as shown in Figure 83
6 1048766 The meter reading value shall be less than 1 ohm Figure 83 - Live and Neutral
Conductor Continuity Test Ohm Meter
Insulation Resistance Test
69 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
i Ensure that there is no leakage current between phase conductors phase and neutral conductors and
phase conductor and earth
ii Test the strength of the cable insulation
iii Test Equipment ndash Insulation Resistance Tester Operating voltage is 250VDC or 500VDC
iv Test Method
1 1048766 Switch off main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in the Table below
5 1048766 Meter reading value shall be less than 1 Megaohm
Polarity Test
i Ensure that each fuse or single pole control and protection device is connected only in the phase
conductor
ii Intermediate contact of Edison screw lamp holder is connected to the phase conductor
iii Ensure that phase neutral and earth conductors at socket outlets are connected at the correct
terminals
iv Test Equipment ndash Multimeter (Ohm range) or Ohm meter
v Test Method
1 1048766 Switch off Main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in Figure 85
5 1048766 Test switches and single phase control devices at the phase conductors
6 1048766 Test socket outlet connection sources
7 1048766 Test Edison screw lamp holder connections
8 1048766 Meter reading value shall be less than 1 Ω
Earth Electrode Resistance Test
i To test the earth electrode resistance
70 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
ii To ascertain the suitability of the location of the electrode
iii To ensure that the electrode is not buried within the resistance area of another electrode
iv Test equipment ndash Earth Resistance Tester
v Test method -
1 1048766 Terminal rsquoErsquo is connected to the electrode to be tested (green conductor)
2 1048766 Terminal lsquoPrsquo is connected to the potential spike (yellow conductor) at a distance of 10
meters from the earth electrode
3 1048766 Terminal lsquoCrsquo is connected to the current spike (red conductor) at a distance of 20 meters
from the earth electrode E P C Electrode 10 meter 10 meter
Figure 86 ndash Earth Electrode Resistance Measurement Test Equipment
Earth Electrode Resistance Measurement Method (Figure 86)
This test must be repeated at least three times to ensure that the reading is not affected by interacting
earthing regions
i Record the first reading (Z1) Example Z1 = 10 Ω
ii Move the voltage spike to a distance of 6 meters from the original position Record the second
reading (Z2) Example Z2 = 10 Ω
iii Move the voltage spike to a distance of 6 meters from the original position Record the third
reading (Z3)
Example Z3 = 10 Ω
Residual Current Device Test
71 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
i Ensure that the residual current device (RCD) trips within the set time on the occurrence of current
leakage to earth
ii Test Equipment ndash RCD Tester RCCB Tester
iii Test Method 1
1 1048766 Use the Trip Test Button
2 1048766 Press the trip button found on the RCD to determine if it trips or otherwise This test would
not be able to determine the sensitivity of the RCD nor the time taken for it to trip
iv Test Method 2
1048766 Use a RCD Tester
This equipment is equipped with a 13A plug which can be connected to a 13A socket outlet Select the
RCD sensitivity to be the same as the sensitivity of the RCD to be tested to determine if the RCD can
trip The time to trip shall not exceed 40 mS
1048766 Test method ndash
a) Position the selection switch in accordance with the sensitivity of the RCD used
Example 100 mA 01 A
b) Position the operations switch to lsquoNo Triprsquo (frac12 Rated mA = 50) connect the 3 pin plug to
the 13A socket outlet
c) Switch on the 13A socket outlet ndash ensure that the P-N and P-E lights light up This shows that
the polarity is correct (Note if both the lights as above do not light up the test cannot be
continued)
d) Press the test button ndash the reading shows less than 200 millisecond and simultaneously the
lsquotestrsquo light lights up and the P-N and P-E lights do not light up At that instant the RCD will
not trip
e) Move the selection switch to 180o (+ve wave) ndash repeat steps (d) and (e) = 100)
f) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
g) Move the selection switch to 0o (-ve wave)
h) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
i) The above test is repeated until a near correct reading is obtained
j) Record the test results
k) Change the operations switch to lsquoFast Triprsquo and press the test button ndash RCD will trip within a
time not exceeding 40 mS
l) Repeat a number of times at 0o or 180o
72 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 9 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (DC)
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
73 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Start stop button 240Vac 5A 2
9 Filament lamp (Bulb ) 240Vac 40W 3
10 Overload Relay 415V 20A 3
11 Three phase induction motor 5 hp 3
12 Single phase step down transformer 2500VA 1
13 Single core PVC insulated Cable 1mm 2 As required
14 Single core PVC insulated Cable 25mm 2 As required
15 DIN rail 35 mm As required
16 PVC type Cable tray 50 mm x 50 mm As required
17 Cable ties 4 ldquo As required
18 Flexible wires 05 mm As required
19 PVC Connectors 5 A amp 20 A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the schematic
diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a optional exercise
i Simple DOL starter
ii Forward reverse DOL starter
iii Forward Reverse Dahlander motor
iv Three motors operated in sequence by DOL starter operated by manual push
button or time delay relay
74 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
a One loop per-cycle
b Continuous operation in a loop
c optional circuit design to represent the same task
v Only one out of three motors to be operated at a time (quiz)
4 Test the functionality of completed project
LESSON 10 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (AC)
75 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 1
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Lamp point 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
76 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
11 Overload Relay 415V 20A 3
12 Three phase induction
motor
5 hp 3
13 Single core PVC insulated
Cable
1mm 2 As required
14 Single core PVC insulated
Cable
25mm 2 As required
15 DIN rail 35 mm As required
16 PVC type Cable tray 50 mm x 50 mm As required
17 Cable ties 4 ldquo As required
18 Flexible wires 05 mm As required
19 PVC Connectors 5 A amp 20 A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the
schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram optional exercise
4 Simple DOL starter
5 Forward reverse DOL starter
6 Test the functionality of completed project
77 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 1
78 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
cm
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Indicating light 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
11 Overload Relay 415V 20A 3
12 Three phase induction motor 5 hp 3
13 Single phase step down
transformer
2500VA 1
14 Single core PVC insulated
Cable
1mm 2 As required
15 Single core PVC insulated
Cable
25mm 2 As required
16 DIN rail 35 mm As required
17 PVC type Cable tray 50 mm x 50 mm As required
18 Cable ties 4 ldquo As required
19 Flexible wires 05 mm As required
20 PVC Connectors 5 A amp 20 A 240 V As required
21 Single pole MCB 6A 240 V 1
22 Single pole MCB 2A 240 V 1
23 Triple pole MCB 20A 415 V 1
24 Mounting board 30 cm x 40 cm x 3
cm
1
25 Relay cw 11 pin socket 10 A 240 Vac 2
26 Time delay relay 10 A 240 Vac 3
27 Triple pole Contactor 20A 240Vac 3
28 Batten type Lamp holder 240Vac 10 A 3
29 Start stop button 240Vac 10A 2
30 Indicating light (Bulb ) 240Vac 25W 3
31 Overload Relay 415V 20A 1
32 Three phase dahlander type
induction motor
5 hp 1
33 Single phase step down
transformer
24024Vac
2500VA
1
79 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
34 Single core PVC insulated
Cable
1mm 2 As required
35 Single core PVC insulated
Cable
25mm 2 As required
36 DIN rail 35 mm As required
37 PVC type Cable tray 50 mm x 50 mm As required
38 Cable ties 4 ldquo As required
39 Flexible wires 075 mm As required
40 PVC Connectors 5 A amp 20 A 240 V As required
41 Terminal block 20A 240Vac As required
Procedures
5 Identify each component according to specification and quantity required from the schematic
diagram attached
6 Test the functionality of each component by using multi-meter or power supply whichever
applicable
7 Wire component according to circuit diagram
8 Three motors operated in sequence by DOL starter operated by manual push button or time
delay relay
a One loop per-cycle
b Continuous operation in a loop
c optional circuit design to represent the same task
d Only one out of three motors to be operated at a time (quiz)
9 Test the functionality of completed project
80 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
BASIC DESIGN INDUSTRIAL MOTOR CONTROL (SEQUENCE CONTROL)
THREE PHASE INDUCTION MOTOR OPERATED IN SEQUENCE BY DIRECT ON LINE
STARTER
LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
81 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
82 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Lcd lamp indicator 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
11 Overload Relay 415V 20A 3
12 Three phase induction motor 5 hp 3
13 Single phase step down transformer 2500VA 1
14 Single core PVC insulated Cable 1mm 2 As required
15 Single core PVC insulated Cable 25mm 2 As required
16 DIN rail 35 mm As required
17 PVC type Cable tray 50 mm x 50 mm As required
18 Cable ties 4 ldquo As required
19 Flexible wires 1 mm Oslash As required
20 PVC Terminal block 10A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the schematic
diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a optional exercise
i Forward Reverse dahlander motor
4 Test the functionality of completed project
83 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
THREE PHASE DAHLANDER TYPE INDUCTION MOTOR OPERATED FORWARD AND
REVERSE OPERATION BY DIRECT ON LINE STARTER
84 ndash 99EASYTECH ENTERPRISE
LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
Introduction
If a motors windings are connected in the star configuration any two phases will be in series across
the supply and hence the line current will be smaller(by 577) than if the windings were connected in
the delta arrangement
Hence larger-type motors with heavy starting currents are first connected in star and then when the
starting currents fall in delta This of course means that all six of the ends of the windings must be
brought to terminations outside the casing (Fig 833)
EZTECH
EZTECH ELECTRICAL INSTALLATION GUIDE
The automatic version of this starter incorporates a timing relay which automatically changes the
connections from star to delta Figs 834 and 835 show the wiring and schematic diagrams for a star
delta starter
Objectives
1 Identify component and the specification
2 Design forward reverse star delta starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
2 ndash 99EASYTECH ENTERPRISE
REV -C
LEGENDMCCB Moulded Case Circuit BreakerTOR Thermal Over Load RelayFOW-C Mains Forward ContactorREV-C Mains Reverse ContactorDC Delta ContactorSC Star ContactorS-SW Mains Selector Switch
SC
V2
W2
U2
DC
V1
W1
U1
TOR
TOR
FOW-C
30A MCCB
TOR
MAIN CIRCUIT FORWARD REVERSE STAR DELTA
RYBN S
-SW
3 PHASEINDUCTION MOTOR
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Relay 10 A 240V 3
5 Triple pole Contactor
6 cw NO NC auxiliary contact
240Vac 20 A 4
7 Overload Relay 415 V 1
8 LED indicator 240vac 5 A 4
9 Start stop button 240Vac 5A 2
10 DIN rail 35 mm As required
11 Flexible wires 1 mm As required
12 Single core PVC insulated
wire
25 mm As required
13 Terminal block 20 A As required
14 Squirrel cage motor 5kW 1
15 5 pin plug and socket 415V 20A 1
16 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
3 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
a Manual star delta
b Manual Forward reverse star delta starter
c Automatic star delta starter
d Automatic Forward reverse star delta starter
4 Test the functionality of completed project
4 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
Objectives
1 Identify component and the specification
2 Design auto transformer starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
5 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Autotransformer starter is used to start a 3 phase induction motor that has a rating between 10 to 15 hp
6 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Autotransformer set 10Kw 415 V 50 Hz 1
5 Triple pole Contactor 240Vac 4
6 Batten type Lamp holder 240 Vac 105 A 4
7 Start stop button 240Vac 10A 4
8 Filament lamp (Bulb ) 240Vac 40W 4
9 DIN rail 35 mm As required
10 Flexible wires 1 mm As required
7 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
11 Single core PVC insulated
wire
25 mm As required
12 Terminal block 20 A As required
13 Squirrel cage motor 10kW 1
14 5 pin plug and socket 415V 20A 1
15 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a open transient autotransformer starter
b close transient autotransformer starter
c Forward reverse autotransformer starter
4 Test the functionality of completed project
8 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
Objectives
1 Identify component and the specification
2 Design rotor resistance starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
9 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Rotor Resistor set 10kW 1
5 Triple pole Contactor 240Vac 20A 4
6 Indicating light 240vac 5 A 4
7 Start stop push button 240Vac 5A 4
8 DIN rail 35 mm As required
9 Flexible wires 1 mm 2 As required
10 Single core PVC insulated wire 25 mm 2 As required
11 Terminal block 20 A As required
12 Slip Ring motor 10kW 1
13 5 pin round 3 phase socket 415V 20A 1
14 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
10 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
4 Test the functionality of completed project
a Dead circuit test b Life circuit test
5 Measure starting and running Amps
LESSON 16
TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
An installation in general will suffer damage
Damage usually occurs on the electric motor control as follows
1 Damage to the main circuit
2 Damage to the control circuit
The cause of the damage
i Overcurrent overload short circuit
ii Leakage current to ground
iii Equipment malfunction
iv The main control circuit
a Trip of main circuit protection devices fire
b Defect of motor terminal such as short circuit fire loose
v The control circuit is not functioning -
a contactor relay relay time overload relay does not work damaged burned
b Loose cable connection disconnected
Detecting and Repairing Damage
Examples of damage are as follows
i Motor does not work
ii Motor function and overload relay trips
iii Motor function but only partially functional control circuit
Methods of detecting damage
Among the known methods necessary to detect damage are as follows
1 Turn off the electricity at the main switch (main switch) in order to avoid any danger during the
work carried out to detect damage
2 Check all the protective gear that controls the motor control main circuit
11 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
3 Make sure the damage function control circuit
4 Check the control circuit according to the schematic circuit diagram of the motor control
5 Check the operation of the control circuit
Note
Use wiring that has been installed on the SYSTEM OF MOTOR CONTROL BOARD by Forward
Reverse control circuit for Star Delta to test and look for damage
SELF-ASSESSMENT QUESTIONS
1 (a) Explain what is meant by the term lsquoback emfrsquo in a motor
(b) Outline the basic differences between series shunt and compound wound dc motors
2 (a) With the aid of diagrams explain how the speed of series shunt and compound-wound motors
may be controlled
(b) A 440V dc shunt-wound motor has a field resistance of 200R and an armature resistance of 06 R
When its speed is 20 rev d second the current drawn from the supply is 122A Calculate its back
emf at this speed If the speed were decreased to 19 revssecond the field flux remaining unchanged
calculate the new back emf and the new armature current
3 A load of 64 kW at 240 V is supplied from the terminals of a shunt-wound dc generator The field
resistance is 180 A Calculate the armature current
4 (a) Explain with the aid of a diagram how a rotating magnetic field may be
(b) What is meant by lsquosynchronous speedrsquo
Calculate the synchronous obtained speed of a 12 pole motor if the supply frequency is 50Hz
5 (a) Explain the action of a synchronous motor
(b) What methods are available to start a synchronous motor Explain with diagrams
6 (a) Explain the action of a cage induction motor
(b) What is meant by the term lsquosliprsquo
Calculate the percentage slip of a six pole induction motor running at 162 revssecond from a 50 Hz
supply
7 Describe with sketches three different ways of starting a single-phase induction motor
12 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
8 Explain with the aid of a sketch the action of a three-phase DOL starter
What are dashpots used for How are remote start and stop buttons connected
9 A I0 kW 240V 50Hz single-phase cage rotor induction motor is 85efficient and has a PF of 068
lagging Calculate the motor current and the value of capacitor required to raise the PF to 093
lagging
10 Calculate the torque developed by an 18 kW four-pole induction motor run at 35 slip from a
50Hz supply
APPENDIX 1
13 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 11
14 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 111
Attachment Reference
httpswwwtlc-directcoukBook621htm
httpwwwstgovmyindexphpms
15 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify types of component and its specification
2 Wire component according to the schematic diagram given
3 Test the functionality of the circuit dead circuit test life circuit test
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board Perforated Metal 1
2 kWh meter 240 V 40 A 1
3 Socket outlet 13A 240Vac 4
4 RCCB 40A Trip Amps
30mA240 Vac
1
5 3 pin socket 240Vac 13A 4
6 Single pole MCB 20A 240 V 2
7 DOL starter 1 kW 240Vac 2
8 1 phase induction motor 2Hp 240 Vac 1
9 Cooker control unit 4kW 240Vac 1
10 Water heater point 4kW 240 Vac 1
11 DIN rail 35 mm As required
12 PVC casing 20mm As required
13 Flexible wires 05 mm As required
14 Terminal block 10 A As required
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Wire two unit of 13 A socket outlet in radial circuit
3 Wire four units of 13 A socket outlet in ring circuit
4 Wire one unit DOL starter for air-conditioner point
5 Wire one unit of cooker control unit point
6 Wire one unit of water heater point
7 Test the functionality of each component by using mmeter or power supply whichever
applicable
8 Wire component according to circuit diagram
9 Test the functionality of completed project dead circuit test life circuit test
Note
35 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Ensure that the correct rating of protection device and size of wire used
LESSON 4ndash CONDUIT BENDING AND TRUNKING FABRICATION TECHNIQUE
Common fitting used in an industrial wiring
Cutting and threading the condute
36 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
37 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
38 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify conduit fitting and the specification
2 Measure and Cut steel conduit according to specified dimension
3 Bend and fabricate conduit at 45 90 according to layout diagram
4 Wire component according to the schematic diagram
5 Test the functionality of the circuit
39 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Conduit Bender Oslash 19 mm ( frac34 ldquo) 1
2 Measuring Tape 3 metre 1
3 Hacksaw frame and blade 30cm 1
4 Conduit cutter 1
5 Pipe Vise 1
6 Pipe Wrench 1
7 Ratchet Dies 20 mm 1
8 Metal trunking 50 mm x 50 mm 1
9 GI conduit 20mm 1
10 End box 20 mm 1
11 Flexible wires 05 mm As required
12 Connectors 5 A As required
13 Single core PVC ins Cable 25 mm 2 As required
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Wire two unit of 13 A socket outlet in radial circuit
3 Wire four unit of 13 A socket outlet in ring circuit
4 Wire one unit DOL starter for air-conditioner point
5 Wire one unit of cooker control unit point
6 Wire one unit of water heater point
7 Test the functionality of each component by using multimeter or power supply whichever
applicable
8 Wire component according to circuit diagram
9 Test the functionality of completed project
Note
Ensure that the rating of protection device and size of wire
K prior to 31 March
2004 (BS 7671)
(formerly)
bare conductor
sleeved at terminations (formerly)
40 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 5 ndashWIRING SYSTEM OF 1 Oslash LIGHTING AND POWER CIRCUIT
POWER CIRCUITSa Radial circuits
Radial circuits are arranged in the same way as item 1 above in lighting layouts in that each socket
outlet is supplied via the previous one
Points to note
1 The number of socket outlets complying with BS 1363 is unlimited for a floor area of up to 50m 2 if
the circuit protection is a 30 A or 32 A cartridge fuse or circuit breaker the cable being 4 mm PVC
copper or 25 mm2 mineral insulated (mi)
2 The number of socket outlets is unlimited for a floor area up to 20 m 2 with any type of circuit
protection of 20 A using 25 mm2 PVC copper cable or 15 mm2 mi
3 The total number of fused spurs is unlimited
b ring final circuits
These circuits are the same as radial circuits except that the final socket outlet is wired back to the
supply position In effect any outlet is supplied from two directions (Fig 152)
Points to note
1 Every twin-socket outlet counts as two single-socket outlets
2 The number of non-fused spurs must not exceed the total number of points on the ring Fig 158
shows seven points on the ring and five spurs
3 The fuse rating of a fused spur box must not exceed 13 A and the current rating of all points supplied
by the fused spur must not exceed 13 A
4 Non-fused spurs must supply no more than one single or one double socket on the ring Fig 158
shows seven points on the ring and five spurs rating of all points supplied by the fused spur must not
exceed 13 A or one stationary appliance
CapacityMain conductor size
copper (mm2)
Earth conductor
size (mm2)
Circuit breaker
capacity (A)
Up to 600 W 15 15 6
600ndash1200 W 1525 15 10
1200ndash1800 W 254 25 16
41 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Ring circuit
(floor area 100 m2)25 15 3032
A2 radial circuit
(floor area 75 m2)40 25 3032
A3 radial circuit
(floor area 50 m2)25 15 20
Air conditioner (15 tonne) 60 60 3032
Cooker 60 60 3032
Water heater 40 40 20
Objectives
1 Identify component and the specification
2 Wire component according to the schematic diagram
3 Test the functionality of the circuit
42 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board Perforated 1
2 Cut out fuse and neutral link 60A 240V 1each
3 kWh meter 240V 40A 1
4 Switched Socket outlet 13A 240Vac 4
5 Single pole two way switch cw switch
box
5A 240Vac 2
6 RCCB ELCB 63 A Tripping current 100mA
415 Vac
1
7 3 pin plug 240Vac 13A 4
8 Single pole MCB 20 A 2
9 Single pole MCB 6A 1
10 Single pole MCB 20A 2
11 DOL starter 240Vac 2
12 1 phase induction motor 2hp 240 Vac 1
13 Self tapping Wood screw As required
14 DIN rail Stainless steel allum35 mm As required
15 PVC pipe 20mm dia As required
16 End box 20 mm dia 4
17 Flexible wires 05 mm 2 As required
18 Connectors 5 A As required
Procedures
43 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
4 Test the functionality of completed project
LESSON 6 ndash WIRING SYSTEM OF 3 Oslash DISTRIBUTION BOARD
Introduction
44 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
45 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
46 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
47 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
48 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify each component and the specification
2 Wire component according to the schematic diagram given
3 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting Board 450 x 600 mm Perforated metal 1
2 5 pin round socket and plug 415V ac 32A 1
3 Cut out fuse 60 A 3
4 Neutral link 1
5 kWatt hour meter 415V 60A 1
6 ELCB RCCB 3P+N In=63A415 Vac I trip= 300mA 1
7 ELCB RCCB 3P+N In=63A415 Vac I trip= 30mA 1
8 Single pole MCB 6A 240 V 3
9 Single pole MCB 20A 240 V 3
10 DOL starter 20 A 240Vac 2
11 Socket outlet 15 A 240 Vac 1
12 Switched Socket outlet 13 A 240 Vac 3
13 Led indicating light 5A 240 Vac 3
14 Single pole 4 gang 1 way switch 5A 240 Vac 2
15 Single pole 2 way switch 5A 240 Vac 2
16 1 phase induction motor 1 kW 240Vac 1
17 Metal trunking 30 mm x30 mm As required
18 Self tapping Wood screw 4 mm x 20 mm As required
19 DIN rail 25 mm x 1mm
20 GI steel rigid conduit 20mm As required
21 Flexible conduit 20mm As required
22 End box 20 mm 4
23 Flexible wires 05 mm 2 As required
24 Single core PVC insulated wire 15 mm 2 As required
25 Single core PVC insulated wires 25 mm 2 As required
26 Terminal block 10 A As required
Procedures
49 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify each components and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
4 Test the functionality of completed project
1 dead circuit test
2 life circuit
Note Proper earthing should be made
50 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 7 ndash WIRING SYSTEM OF THREE PHASE LIGHTING AND POWER CIRCUIT
51 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
52 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify component and the specification
2 Wire component according to the schematic diagram
3 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting bay Board Perforated metal 180 cm x 180 cm 1
2 k Watt hour meter 415V 60A 1
3 MCCB 415V 60A
4 ELCB RCCB In=60A415 Vac I trip=30mA 1
5 5 pin round Socket and
plug
415Vac 32A 4
6 Single pole MCB 6A 1
7 Triple pole MCB 20A 2
8 Triple pole Main switch 60A 1
9 DOL starter 240Vac 2
10 3 phase induction motor 2hp 415 Vac 1
11 1 phase induction motor 1
12 Metal trunking 30 mm x30 mm As required
13 Self tapping Wood screw 4 mm x 20 mm As required
14 DIN rail 25 mm x 1mm
15 GI steel rigid conduit 20mm As required
16 Flexible conduit 20mm As required
17 End box 20 mm 4
18 Flexible wires 05 mm As required
19 Connectors 10 A As required
Procedures
1 Identify each components and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
4 Test the functionality of completed project
1 dead circuit 2 life circuit test
5 Record the current drawn by the load as connected in star and delta
Note Proper earthing should be made
53 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 8 INSPECTION AND TESTING OF ELECTRICAL INSTALLATION
On completion of a wiring installation a number of tests on the installation have to be conducted to
ascertain that the wiring circuits and connected appliances are safe for use Prior to carrying out the
tests an inspection has to be done The results of the inspectionsupervision and test have to be
presented in Form G (as in Appendix IV) and Form H (as in Appendix V)
To have the test certification as in Form H the following tests shall be conducted
i Continuity Test
ii Insulation Resistance Test
iii Polarity Test
iv Earth Electrode Resistance test and
v Residual Current Device Test
1 Continuity Test
There are 3 main types of continuity tests for the final circuits-
i Protection Conductor Continuity Test
ii Final Ring Circuit Conductor Continuity Test
iii Live and Neutral Conductor Continuity Test
a) Protection Conductor Continuity Test
bull To ascertain that all protection conductors are connected in the correct and effective manner
bull Test equipment ndash Multimeter (Ohm range) or Ohm meter
54 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
bull Test Method
1 1048766 Ensure that the main switch RCD and MCB are open circuited (switched off) and all loads
are disconnected
2 1048766 Connected the test leads as in the Figure 81 The meter reading shall be less than 1 Ω
55 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Final Ring Circuit Conductor Continuity Test
bull To ensure that all conductors around the ring circuit have continuity
bull Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
bull Test Method
1 1048766 Disconnect both the supply source live conductors from the MCB the neutral conductor
from the neutral terminals and the earth conductor from the earth terminal in the distribution
fuse box
2 1048766 Connect the test leads as in the Figure 82 (EE)
3 1048766 Repeat the procedure for (L-L) and (N-N)
4 1048766 The meter reading value shall be less than 1 ohm
56 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Live and Neutral Conductor Continuity Test
a To ensure that each conductor in the circuit has continuity
b Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
2 Test Method
1 1048766 Switch off the Main switch RCD and MCB
2 1048766 Disconnect all loads
3 1048766 Switch on all switches in the circuit
4 1048766 Disconnect the fusesfinal circuit breakers and close the circuit
5 1048766 Carry out the test as shown in Figure 83
6 1048766 The meter reading value shall be less than 1Ω
57 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
58 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
CONTINUITY TEST
Insulation Resistance Test
i Ensure that there is no leakage current between phase conductors phase and neutral conductors and
phase conductor and earth
ii Test the strength of the cable insulation
iii Test Equipment ndash Insulation Resistance Tester operating voltage is 250VDC or 500VDC
iv Test Method
1 1048766 Switch off main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
59 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
4 1048766 Carry out test as in the Table below
5 1048766 Meter reading value shall be less than 1 Megaohm
60 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
61 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Insulation resitance test
62 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
INSULATION RESISTANCE TEST BETWEEN CONDUCTORS AND OPPOSITE POLARITY
Polarity Testi Ensure that each fuse or single pole control and protection device is connected only in the phase
conductor
ii Intermediate contact of Edison screw lamp holder is connected to the phase conductor
iii Ensure that phase neutral and earth conductors at socket outlets are connected at the correct
terminals
iv Test Equipment ndash Multimeter (Ohm range) or Ohm meter
v Test Method
1 1048766 Switch off Main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in Figure 85
63 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
5 1048766 Test switches and single phase control devices at the phase conductors
6 1048766 Test socket outlet connection sources
7 1048766 Test Edison screw lamp holder connections
8 1048766 Meter reading value shall be less than 1 Ω
64 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Polarity test
65 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Earth Electrode Resistance Testi To test the earth electrode resistance
ii To ascertain the suitability of the location of the electrode
iii To ensure that the electrode is not buried within the resistance area of another electrode
iv Test equipment ndash Earth Resistance Tester
v Test method -
1 1048766 Terminal rsquoErsquo is connected to the electrode to be tested (green conductor)
2 1048766 Terminal lsquoPrsquo is connected to the potential spike (yellow conductor) at a distance of 10
meters from the earth electrode
3 1048766 Terminal lsquoCrsquo is connected to the current spike (red conductor) at a distance of 20 meters
from the earth electrode
Earth Electrode Resistance Measurement Method (Figure 86)
This test must be repeated at least three times to ensure that the reading is not affected by interacting
earthing regions
i Record the first reading (Z1) Example Z1 = 10 Ω
ii Move the voltage spike to a distance of 6 meters from the original position Record the second
reading (Z2 ) Example Z2 = 10 Ω
iii Move the voltage spike to a distance of 6 meters from the original position Record the third
reading (Z3) Example Z3 = 10 Ω
66 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Residual Current Device Testi Ensure that the residual current device (RCD) trips within the set time on the occurrence of current
leakage to earth
ii Test Equipment ndash RCD Tester RCCB Tester
iii Test Method 1
1 1048766 Use the Trip Test Button
2 1048766 Press the trip button found on the RCD to determine if it trips or otherwise This test would
not be able to determine the sensitivity of the RCD nor the time taken for it to trip
iv Test Method 2
i 1048766 Use a RCD Tester
ii This equipment is equipped with a 13A plug which can be connected to a 13A socket outlet
Select the RCD sensitivity to be the same as the sensitivity of the RCD to be tested to
determine if the RCD can trip The time to trip shall not exceed 40 mS
iii 1048766 Test method ndash
a) Position the selection switch in accordance with the sensitivity of the RCD used
Example 100 mA 01 A
b) Position the operations switch to lsquoNo Triprsquo (frac12 Rated mA = 50) connect the 3 pin plug to
the 13A socket outlet
67 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
c) Switch on the 13A socket outlet ndash ensure that the P-N and P-E lights light up
This shows that the polarity is correct (Note if both the lights as above do not light up the test cannot
be continued)
d) Press the test button ndash the reading shows less than 200 mS and simultaneously the lsquotestrsquo light lights
up and the P-N and P-E lights do not light up At that instant the RCD will not trip
e) Move the selection switch to 180o (+ve wave) ndash repeat steps (d) and (e) Move the operations
switch to lsquoTriprsquo (Rated mA = 100)
g) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200mS
h) Move the selection switch to 0o (-ve wave)
i) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
j) The above test is repeated until a near correct reading is obtained
k) Record the test results
l) Change the operations switch to lsquoFast Triprsquo and press the test button ndash RCD will trip within a
time not exceeding 40 millisecond
m) Repeat a number of times at 0o or 180o
On completion of a wiring installation a number of tests on the installation have to be conducted to
ascertain that the wiring circuits and connected appliances are safe for use Prior to carrying out the
tests an inspection has to be done the following tests shall be conducted
i Continuity Test
ii Insulation Resistance Test
iii Polarity Test
iv Earth Electrode Resistance test and
v Residual Current Device Test
821 Continuity Test
There are 3 main types of continuity tests for the final circuits-
i Protection Conductor Continuity Test
ii Final Ring Circuit Conductor Continuity Test
68 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
iii Live and Neutral Conductor Continuity Test
a) Protection Conductor Continuity Test
bull To ascertain that all protection conductors are connected in the correct and effective manner
bull Test equipment ndash Multimeter (Ohm range) or Ohm meter
bull Test Method
1 1048766 Ensure that the main switch RCD and MCB are open circuited (switched off) and all loads are
disconnected
2 1048766 Connected the test leads as in the Figure 81
3 1048766 The meter reading shall be less than 1 Ω
Final Ring Circuit Conductor Continuity Test
bull To ensure that all conductors around the ring circuit have continuity
bull Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
bull Test Method
1 1048766 Disconnect both the supply source live conductors from the MCB the neutral conductor
from the neutral terminals and the earth conductor from the earth terminal in the distribution
fuse box
2 1048766 Connect the test leads as in the Figure 82 (EE)
3 1048766 Repeat the procedure for (L-L) and (N-N)
4 1048766 The meter reading value shall be less than 1 ohm Figure 82 - Final Ring Circuit Conductor
Continuity Test Ohm Meter
Disconnect both the supply source cables from mcbfuse
Take readings at earth conductors of both sources and note resistance readings
Live and Neutral Conductor Continuity Test
1 To ensure that each conductor in the circuit has continuity
2 Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
3 Test Method
1 1048766 Switch off the Main switch RCD and MCB
2 1048766 Disconnect all loads
3 1048766 Switch on all switches in the circuit
4 1048766 Disconnect the fusesfinal circuit breakers and close the circuit
5 1048766 Carry out the test as shown in Figure 83
6 1048766 The meter reading value shall be less than 1 ohm Figure 83 - Live and Neutral
Conductor Continuity Test Ohm Meter
Insulation Resistance Test
69 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
i Ensure that there is no leakage current between phase conductors phase and neutral conductors and
phase conductor and earth
ii Test the strength of the cable insulation
iii Test Equipment ndash Insulation Resistance Tester Operating voltage is 250VDC or 500VDC
iv Test Method
1 1048766 Switch off main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in the Table below
5 1048766 Meter reading value shall be less than 1 Megaohm
Polarity Test
i Ensure that each fuse or single pole control and protection device is connected only in the phase
conductor
ii Intermediate contact of Edison screw lamp holder is connected to the phase conductor
iii Ensure that phase neutral and earth conductors at socket outlets are connected at the correct
terminals
iv Test Equipment ndash Multimeter (Ohm range) or Ohm meter
v Test Method
1 1048766 Switch off Main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in Figure 85
5 1048766 Test switches and single phase control devices at the phase conductors
6 1048766 Test socket outlet connection sources
7 1048766 Test Edison screw lamp holder connections
8 1048766 Meter reading value shall be less than 1 Ω
Earth Electrode Resistance Test
i To test the earth electrode resistance
70 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
ii To ascertain the suitability of the location of the electrode
iii To ensure that the electrode is not buried within the resistance area of another electrode
iv Test equipment ndash Earth Resistance Tester
v Test method -
1 1048766 Terminal rsquoErsquo is connected to the electrode to be tested (green conductor)
2 1048766 Terminal lsquoPrsquo is connected to the potential spike (yellow conductor) at a distance of 10
meters from the earth electrode
3 1048766 Terminal lsquoCrsquo is connected to the current spike (red conductor) at a distance of 20 meters
from the earth electrode E P C Electrode 10 meter 10 meter
Figure 86 ndash Earth Electrode Resistance Measurement Test Equipment
Earth Electrode Resistance Measurement Method (Figure 86)
This test must be repeated at least three times to ensure that the reading is not affected by interacting
earthing regions
i Record the first reading (Z1) Example Z1 = 10 Ω
ii Move the voltage spike to a distance of 6 meters from the original position Record the second
reading (Z2) Example Z2 = 10 Ω
iii Move the voltage spike to a distance of 6 meters from the original position Record the third
reading (Z3)
Example Z3 = 10 Ω
Residual Current Device Test
71 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
i Ensure that the residual current device (RCD) trips within the set time on the occurrence of current
leakage to earth
ii Test Equipment ndash RCD Tester RCCB Tester
iii Test Method 1
1 1048766 Use the Trip Test Button
2 1048766 Press the trip button found on the RCD to determine if it trips or otherwise This test would
not be able to determine the sensitivity of the RCD nor the time taken for it to trip
iv Test Method 2
1048766 Use a RCD Tester
This equipment is equipped with a 13A plug which can be connected to a 13A socket outlet Select the
RCD sensitivity to be the same as the sensitivity of the RCD to be tested to determine if the RCD can
trip The time to trip shall not exceed 40 mS
1048766 Test method ndash
a) Position the selection switch in accordance with the sensitivity of the RCD used
Example 100 mA 01 A
b) Position the operations switch to lsquoNo Triprsquo (frac12 Rated mA = 50) connect the 3 pin plug to
the 13A socket outlet
c) Switch on the 13A socket outlet ndash ensure that the P-N and P-E lights light up This shows that
the polarity is correct (Note if both the lights as above do not light up the test cannot be
continued)
d) Press the test button ndash the reading shows less than 200 millisecond and simultaneously the
lsquotestrsquo light lights up and the P-N and P-E lights do not light up At that instant the RCD will
not trip
e) Move the selection switch to 180o (+ve wave) ndash repeat steps (d) and (e) = 100)
f) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
g) Move the selection switch to 0o (-ve wave)
h) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
i) The above test is repeated until a near correct reading is obtained
j) Record the test results
k) Change the operations switch to lsquoFast Triprsquo and press the test button ndash RCD will trip within a
time not exceeding 40 mS
l) Repeat a number of times at 0o or 180o
72 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 9 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (DC)
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
73 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Start stop button 240Vac 5A 2
9 Filament lamp (Bulb ) 240Vac 40W 3
10 Overload Relay 415V 20A 3
11 Three phase induction motor 5 hp 3
12 Single phase step down transformer 2500VA 1
13 Single core PVC insulated Cable 1mm 2 As required
14 Single core PVC insulated Cable 25mm 2 As required
15 DIN rail 35 mm As required
16 PVC type Cable tray 50 mm x 50 mm As required
17 Cable ties 4 ldquo As required
18 Flexible wires 05 mm As required
19 PVC Connectors 5 A amp 20 A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the schematic
diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a optional exercise
i Simple DOL starter
ii Forward reverse DOL starter
iii Forward Reverse Dahlander motor
iv Three motors operated in sequence by DOL starter operated by manual push
button or time delay relay
74 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
a One loop per-cycle
b Continuous operation in a loop
c optional circuit design to represent the same task
v Only one out of three motors to be operated at a time (quiz)
4 Test the functionality of completed project
LESSON 10 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (AC)
75 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 1
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Lamp point 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
76 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
11 Overload Relay 415V 20A 3
12 Three phase induction
motor
5 hp 3
13 Single core PVC insulated
Cable
1mm 2 As required
14 Single core PVC insulated
Cable
25mm 2 As required
15 DIN rail 35 mm As required
16 PVC type Cable tray 50 mm x 50 mm As required
17 Cable ties 4 ldquo As required
18 Flexible wires 05 mm As required
19 PVC Connectors 5 A amp 20 A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the
schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram optional exercise
4 Simple DOL starter
5 Forward reverse DOL starter
6 Test the functionality of completed project
77 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 1
78 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
cm
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Indicating light 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
11 Overload Relay 415V 20A 3
12 Three phase induction motor 5 hp 3
13 Single phase step down
transformer
2500VA 1
14 Single core PVC insulated
Cable
1mm 2 As required
15 Single core PVC insulated
Cable
25mm 2 As required
16 DIN rail 35 mm As required
17 PVC type Cable tray 50 mm x 50 mm As required
18 Cable ties 4 ldquo As required
19 Flexible wires 05 mm As required
20 PVC Connectors 5 A amp 20 A 240 V As required
21 Single pole MCB 6A 240 V 1
22 Single pole MCB 2A 240 V 1
23 Triple pole MCB 20A 415 V 1
24 Mounting board 30 cm x 40 cm x 3
cm
1
25 Relay cw 11 pin socket 10 A 240 Vac 2
26 Time delay relay 10 A 240 Vac 3
27 Triple pole Contactor 20A 240Vac 3
28 Batten type Lamp holder 240Vac 10 A 3
29 Start stop button 240Vac 10A 2
30 Indicating light (Bulb ) 240Vac 25W 3
31 Overload Relay 415V 20A 1
32 Three phase dahlander type
induction motor
5 hp 1
33 Single phase step down
transformer
24024Vac
2500VA
1
79 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
34 Single core PVC insulated
Cable
1mm 2 As required
35 Single core PVC insulated
Cable
25mm 2 As required
36 DIN rail 35 mm As required
37 PVC type Cable tray 50 mm x 50 mm As required
38 Cable ties 4 ldquo As required
39 Flexible wires 075 mm As required
40 PVC Connectors 5 A amp 20 A 240 V As required
41 Terminal block 20A 240Vac As required
Procedures
5 Identify each component according to specification and quantity required from the schematic
diagram attached
6 Test the functionality of each component by using multi-meter or power supply whichever
applicable
7 Wire component according to circuit diagram
8 Three motors operated in sequence by DOL starter operated by manual push button or time
delay relay
a One loop per-cycle
b Continuous operation in a loop
c optional circuit design to represent the same task
d Only one out of three motors to be operated at a time (quiz)
9 Test the functionality of completed project
80 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
BASIC DESIGN INDUSTRIAL MOTOR CONTROL (SEQUENCE CONTROL)
THREE PHASE INDUCTION MOTOR OPERATED IN SEQUENCE BY DIRECT ON LINE
STARTER
LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
81 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
82 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Lcd lamp indicator 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
11 Overload Relay 415V 20A 3
12 Three phase induction motor 5 hp 3
13 Single phase step down transformer 2500VA 1
14 Single core PVC insulated Cable 1mm 2 As required
15 Single core PVC insulated Cable 25mm 2 As required
16 DIN rail 35 mm As required
17 PVC type Cable tray 50 mm x 50 mm As required
18 Cable ties 4 ldquo As required
19 Flexible wires 1 mm Oslash As required
20 PVC Terminal block 10A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the schematic
diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a optional exercise
i Forward Reverse dahlander motor
4 Test the functionality of completed project
83 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
THREE PHASE DAHLANDER TYPE INDUCTION MOTOR OPERATED FORWARD AND
REVERSE OPERATION BY DIRECT ON LINE STARTER
84 ndash 99EASYTECH ENTERPRISE
LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
Introduction
If a motors windings are connected in the star configuration any two phases will be in series across
the supply and hence the line current will be smaller(by 577) than if the windings were connected in
the delta arrangement
Hence larger-type motors with heavy starting currents are first connected in star and then when the
starting currents fall in delta This of course means that all six of the ends of the windings must be
brought to terminations outside the casing (Fig 833)
EZTECH
EZTECH ELECTRICAL INSTALLATION GUIDE
The automatic version of this starter incorporates a timing relay which automatically changes the
connections from star to delta Figs 834 and 835 show the wiring and schematic diagrams for a star
delta starter
Objectives
1 Identify component and the specification
2 Design forward reverse star delta starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
2 ndash 99EASYTECH ENTERPRISE
REV -C
LEGENDMCCB Moulded Case Circuit BreakerTOR Thermal Over Load RelayFOW-C Mains Forward ContactorREV-C Mains Reverse ContactorDC Delta ContactorSC Star ContactorS-SW Mains Selector Switch
SC
V2
W2
U2
DC
V1
W1
U1
TOR
TOR
FOW-C
30A MCCB
TOR
MAIN CIRCUIT FORWARD REVERSE STAR DELTA
RYBN S
-SW
3 PHASEINDUCTION MOTOR
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Relay 10 A 240V 3
5 Triple pole Contactor
6 cw NO NC auxiliary contact
240Vac 20 A 4
7 Overload Relay 415 V 1
8 LED indicator 240vac 5 A 4
9 Start stop button 240Vac 5A 2
10 DIN rail 35 mm As required
11 Flexible wires 1 mm As required
12 Single core PVC insulated
wire
25 mm As required
13 Terminal block 20 A As required
14 Squirrel cage motor 5kW 1
15 5 pin plug and socket 415V 20A 1
16 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
3 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
a Manual star delta
b Manual Forward reverse star delta starter
c Automatic star delta starter
d Automatic Forward reverse star delta starter
4 Test the functionality of completed project
4 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
Objectives
1 Identify component and the specification
2 Design auto transformer starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
5 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Autotransformer starter is used to start a 3 phase induction motor that has a rating between 10 to 15 hp
6 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Autotransformer set 10Kw 415 V 50 Hz 1
5 Triple pole Contactor 240Vac 4
6 Batten type Lamp holder 240 Vac 105 A 4
7 Start stop button 240Vac 10A 4
8 Filament lamp (Bulb ) 240Vac 40W 4
9 DIN rail 35 mm As required
10 Flexible wires 1 mm As required
7 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
11 Single core PVC insulated
wire
25 mm As required
12 Terminal block 20 A As required
13 Squirrel cage motor 10kW 1
14 5 pin plug and socket 415V 20A 1
15 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a open transient autotransformer starter
b close transient autotransformer starter
c Forward reverse autotransformer starter
4 Test the functionality of completed project
8 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
Objectives
1 Identify component and the specification
2 Design rotor resistance starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
9 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Rotor Resistor set 10kW 1
5 Triple pole Contactor 240Vac 20A 4
6 Indicating light 240vac 5 A 4
7 Start stop push button 240Vac 5A 4
8 DIN rail 35 mm As required
9 Flexible wires 1 mm 2 As required
10 Single core PVC insulated wire 25 mm 2 As required
11 Terminal block 20 A As required
12 Slip Ring motor 10kW 1
13 5 pin round 3 phase socket 415V 20A 1
14 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
10 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
4 Test the functionality of completed project
a Dead circuit test b Life circuit test
5 Measure starting and running Amps
LESSON 16
TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
An installation in general will suffer damage
Damage usually occurs on the electric motor control as follows
1 Damage to the main circuit
2 Damage to the control circuit
The cause of the damage
i Overcurrent overload short circuit
ii Leakage current to ground
iii Equipment malfunction
iv The main control circuit
a Trip of main circuit protection devices fire
b Defect of motor terminal such as short circuit fire loose
v The control circuit is not functioning -
a contactor relay relay time overload relay does not work damaged burned
b Loose cable connection disconnected
Detecting and Repairing Damage
Examples of damage are as follows
i Motor does not work
ii Motor function and overload relay trips
iii Motor function but only partially functional control circuit
Methods of detecting damage
Among the known methods necessary to detect damage are as follows
1 Turn off the electricity at the main switch (main switch) in order to avoid any danger during the
work carried out to detect damage
2 Check all the protective gear that controls the motor control main circuit
11 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
3 Make sure the damage function control circuit
4 Check the control circuit according to the schematic circuit diagram of the motor control
5 Check the operation of the control circuit
Note
Use wiring that has been installed on the SYSTEM OF MOTOR CONTROL BOARD by Forward
Reverse control circuit for Star Delta to test and look for damage
SELF-ASSESSMENT QUESTIONS
1 (a) Explain what is meant by the term lsquoback emfrsquo in a motor
(b) Outline the basic differences between series shunt and compound wound dc motors
2 (a) With the aid of diagrams explain how the speed of series shunt and compound-wound motors
may be controlled
(b) A 440V dc shunt-wound motor has a field resistance of 200R and an armature resistance of 06 R
When its speed is 20 rev d second the current drawn from the supply is 122A Calculate its back
emf at this speed If the speed were decreased to 19 revssecond the field flux remaining unchanged
calculate the new back emf and the new armature current
3 A load of 64 kW at 240 V is supplied from the terminals of a shunt-wound dc generator The field
resistance is 180 A Calculate the armature current
4 (a) Explain with the aid of a diagram how a rotating magnetic field may be
(b) What is meant by lsquosynchronous speedrsquo
Calculate the synchronous obtained speed of a 12 pole motor if the supply frequency is 50Hz
5 (a) Explain the action of a synchronous motor
(b) What methods are available to start a synchronous motor Explain with diagrams
6 (a) Explain the action of a cage induction motor
(b) What is meant by the term lsquosliprsquo
Calculate the percentage slip of a six pole induction motor running at 162 revssecond from a 50 Hz
supply
7 Describe with sketches three different ways of starting a single-phase induction motor
12 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
8 Explain with the aid of a sketch the action of a three-phase DOL starter
What are dashpots used for How are remote start and stop buttons connected
9 A I0 kW 240V 50Hz single-phase cage rotor induction motor is 85efficient and has a PF of 068
lagging Calculate the motor current and the value of capacitor required to raise the PF to 093
lagging
10 Calculate the torque developed by an 18 kW four-pole induction motor run at 35 slip from a
50Hz supply
APPENDIX 1
13 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 11
14 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 111
Attachment Reference
httpswwwtlc-directcoukBook621htm
httpwwwstgovmyindexphpms
15 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Ensure that the correct rating of protection device and size of wire used
LESSON 4ndash CONDUIT BENDING AND TRUNKING FABRICATION TECHNIQUE
Common fitting used in an industrial wiring
Cutting and threading the condute
36 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
37 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
38 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify conduit fitting and the specification
2 Measure and Cut steel conduit according to specified dimension
3 Bend and fabricate conduit at 45 90 according to layout diagram
4 Wire component according to the schematic diagram
5 Test the functionality of the circuit
39 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Conduit Bender Oslash 19 mm ( frac34 ldquo) 1
2 Measuring Tape 3 metre 1
3 Hacksaw frame and blade 30cm 1
4 Conduit cutter 1
5 Pipe Vise 1
6 Pipe Wrench 1
7 Ratchet Dies 20 mm 1
8 Metal trunking 50 mm x 50 mm 1
9 GI conduit 20mm 1
10 End box 20 mm 1
11 Flexible wires 05 mm As required
12 Connectors 5 A As required
13 Single core PVC ins Cable 25 mm 2 As required
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Wire two unit of 13 A socket outlet in radial circuit
3 Wire four unit of 13 A socket outlet in ring circuit
4 Wire one unit DOL starter for air-conditioner point
5 Wire one unit of cooker control unit point
6 Wire one unit of water heater point
7 Test the functionality of each component by using multimeter or power supply whichever
applicable
8 Wire component according to circuit diagram
9 Test the functionality of completed project
Note
Ensure that the rating of protection device and size of wire
K prior to 31 March
2004 (BS 7671)
(formerly)
bare conductor
sleeved at terminations (formerly)
40 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 5 ndashWIRING SYSTEM OF 1 Oslash LIGHTING AND POWER CIRCUIT
POWER CIRCUITSa Radial circuits
Radial circuits are arranged in the same way as item 1 above in lighting layouts in that each socket
outlet is supplied via the previous one
Points to note
1 The number of socket outlets complying with BS 1363 is unlimited for a floor area of up to 50m 2 if
the circuit protection is a 30 A or 32 A cartridge fuse or circuit breaker the cable being 4 mm PVC
copper or 25 mm2 mineral insulated (mi)
2 The number of socket outlets is unlimited for a floor area up to 20 m 2 with any type of circuit
protection of 20 A using 25 mm2 PVC copper cable or 15 mm2 mi
3 The total number of fused spurs is unlimited
b ring final circuits
These circuits are the same as radial circuits except that the final socket outlet is wired back to the
supply position In effect any outlet is supplied from two directions (Fig 152)
Points to note
1 Every twin-socket outlet counts as two single-socket outlets
2 The number of non-fused spurs must not exceed the total number of points on the ring Fig 158
shows seven points on the ring and five spurs
3 The fuse rating of a fused spur box must not exceed 13 A and the current rating of all points supplied
by the fused spur must not exceed 13 A
4 Non-fused spurs must supply no more than one single or one double socket on the ring Fig 158
shows seven points on the ring and five spurs rating of all points supplied by the fused spur must not
exceed 13 A or one stationary appliance
CapacityMain conductor size
copper (mm2)
Earth conductor
size (mm2)
Circuit breaker
capacity (A)
Up to 600 W 15 15 6
600ndash1200 W 1525 15 10
1200ndash1800 W 254 25 16
41 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Ring circuit
(floor area 100 m2)25 15 3032
A2 radial circuit
(floor area 75 m2)40 25 3032
A3 radial circuit
(floor area 50 m2)25 15 20
Air conditioner (15 tonne) 60 60 3032
Cooker 60 60 3032
Water heater 40 40 20
Objectives
1 Identify component and the specification
2 Wire component according to the schematic diagram
3 Test the functionality of the circuit
42 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board Perforated 1
2 Cut out fuse and neutral link 60A 240V 1each
3 kWh meter 240V 40A 1
4 Switched Socket outlet 13A 240Vac 4
5 Single pole two way switch cw switch
box
5A 240Vac 2
6 RCCB ELCB 63 A Tripping current 100mA
415 Vac
1
7 3 pin plug 240Vac 13A 4
8 Single pole MCB 20 A 2
9 Single pole MCB 6A 1
10 Single pole MCB 20A 2
11 DOL starter 240Vac 2
12 1 phase induction motor 2hp 240 Vac 1
13 Self tapping Wood screw As required
14 DIN rail Stainless steel allum35 mm As required
15 PVC pipe 20mm dia As required
16 End box 20 mm dia 4
17 Flexible wires 05 mm 2 As required
18 Connectors 5 A As required
Procedures
43 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
4 Test the functionality of completed project
LESSON 6 ndash WIRING SYSTEM OF 3 Oslash DISTRIBUTION BOARD
Introduction
44 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
45 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
46 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
47 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
48 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify each component and the specification
2 Wire component according to the schematic diagram given
3 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting Board 450 x 600 mm Perforated metal 1
2 5 pin round socket and plug 415V ac 32A 1
3 Cut out fuse 60 A 3
4 Neutral link 1
5 kWatt hour meter 415V 60A 1
6 ELCB RCCB 3P+N In=63A415 Vac I trip= 300mA 1
7 ELCB RCCB 3P+N In=63A415 Vac I trip= 30mA 1
8 Single pole MCB 6A 240 V 3
9 Single pole MCB 20A 240 V 3
10 DOL starter 20 A 240Vac 2
11 Socket outlet 15 A 240 Vac 1
12 Switched Socket outlet 13 A 240 Vac 3
13 Led indicating light 5A 240 Vac 3
14 Single pole 4 gang 1 way switch 5A 240 Vac 2
15 Single pole 2 way switch 5A 240 Vac 2
16 1 phase induction motor 1 kW 240Vac 1
17 Metal trunking 30 mm x30 mm As required
18 Self tapping Wood screw 4 mm x 20 mm As required
19 DIN rail 25 mm x 1mm
20 GI steel rigid conduit 20mm As required
21 Flexible conduit 20mm As required
22 End box 20 mm 4
23 Flexible wires 05 mm 2 As required
24 Single core PVC insulated wire 15 mm 2 As required
25 Single core PVC insulated wires 25 mm 2 As required
26 Terminal block 10 A As required
Procedures
49 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify each components and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
4 Test the functionality of completed project
1 dead circuit test
2 life circuit
Note Proper earthing should be made
50 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 7 ndash WIRING SYSTEM OF THREE PHASE LIGHTING AND POWER CIRCUIT
51 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
52 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify component and the specification
2 Wire component according to the schematic diagram
3 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting bay Board Perforated metal 180 cm x 180 cm 1
2 k Watt hour meter 415V 60A 1
3 MCCB 415V 60A
4 ELCB RCCB In=60A415 Vac I trip=30mA 1
5 5 pin round Socket and
plug
415Vac 32A 4
6 Single pole MCB 6A 1
7 Triple pole MCB 20A 2
8 Triple pole Main switch 60A 1
9 DOL starter 240Vac 2
10 3 phase induction motor 2hp 415 Vac 1
11 1 phase induction motor 1
12 Metal trunking 30 mm x30 mm As required
13 Self tapping Wood screw 4 mm x 20 mm As required
14 DIN rail 25 mm x 1mm
15 GI steel rigid conduit 20mm As required
16 Flexible conduit 20mm As required
17 End box 20 mm 4
18 Flexible wires 05 mm As required
19 Connectors 10 A As required
Procedures
1 Identify each components and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
4 Test the functionality of completed project
1 dead circuit 2 life circuit test
5 Record the current drawn by the load as connected in star and delta
Note Proper earthing should be made
53 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 8 INSPECTION AND TESTING OF ELECTRICAL INSTALLATION
On completion of a wiring installation a number of tests on the installation have to be conducted to
ascertain that the wiring circuits and connected appliances are safe for use Prior to carrying out the
tests an inspection has to be done The results of the inspectionsupervision and test have to be
presented in Form G (as in Appendix IV) and Form H (as in Appendix V)
To have the test certification as in Form H the following tests shall be conducted
i Continuity Test
ii Insulation Resistance Test
iii Polarity Test
iv Earth Electrode Resistance test and
v Residual Current Device Test
1 Continuity Test
There are 3 main types of continuity tests for the final circuits-
i Protection Conductor Continuity Test
ii Final Ring Circuit Conductor Continuity Test
iii Live and Neutral Conductor Continuity Test
a) Protection Conductor Continuity Test
bull To ascertain that all protection conductors are connected in the correct and effective manner
bull Test equipment ndash Multimeter (Ohm range) or Ohm meter
54 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
bull Test Method
1 1048766 Ensure that the main switch RCD and MCB are open circuited (switched off) and all loads
are disconnected
2 1048766 Connected the test leads as in the Figure 81 The meter reading shall be less than 1 Ω
55 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Final Ring Circuit Conductor Continuity Test
bull To ensure that all conductors around the ring circuit have continuity
bull Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
bull Test Method
1 1048766 Disconnect both the supply source live conductors from the MCB the neutral conductor
from the neutral terminals and the earth conductor from the earth terminal in the distribution
fuse box
2 1048766 Connect the test leads as in the Figure 82 (EE)
3 1048766 Repeat the procedure for (L-L) and (N-N)
4 1048766 The meter reading value shall be less than 1 ohm
56 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Live and Neutral Conductor Continuity Test
a To ensure that each conductor in the circuit has continuity
b Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
2 Test Method
1 1048766 Switch off the Main switch RCD and MCB
2 1048766 Disconnect all loads
3 1048766 Switch on all switches in the circuit
4 1048766 Disconnect the fusesfinal circuit breakers and close the circuit
5 1048766 Carry out the test as shown in Figure 83
6 1048766 The meter reading value shall be less than 1Ω
57 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
58 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
CONTINUITY TEST
Insulation Resistance Test
i Ensure that there is no leakage current between phase conductors phase and neutral conductors and
phase conductor and earth
ii Test the strength of the cable insulation
iii Test Equipment ndash Insulation Resistance Tester operating voltage is 250VDC or 500VDC
iv Test Method
1 1048766 Switch off main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
59 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
4 1048766 Carry out test as in the Table below
5 1048766 Meter reading value shall be less than 1 Megaohm
60 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
61 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Insulation resitance test
62 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
INSULATION RESISTANCE TEST BETWEEN CONDUCTORS AND OPPOSITE POLARITY
Polarity Testi Ensure that each fuse or single pole control and protection device is connected only in the phase
conductor
ii Intermediate contact of Edison screw lamp holder is connected to the phase conductor
iii Ensure that phase neutral and earth conductors at socket outlets are connected at the correct
terminals
iv Test Equipment ndash Multimeter (Ohm range) or Ohm meter
v Test Method
1 1048766 Switch off Main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in Figure 85
63 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
5 1048766 Test switches and single phase control devices at the phase conductors
6 1048766 Test socket outlet connection sources
7 1048766 Test Edison screw lamp holder connections
8 1048766 Meter reading value shall be less than 1 Ω
64 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Polarity test
65 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Earth Electrode Resistance Testi To test the earth electrode resistance
ii To ascertain the suitability of the location of the electrode
iii To ensure that the electrode is not buried within the resistance area of another electrode
iv Test equipment ndash Earth Resistance Tester
v Test method -
1 1048766 Terminal rsquoErsquo is connected to the electrode to be tested (green conductor)
2 1048766 Terminal lsquoPrsquo is connected to the potential spike (yellow conductor) at a distance of 10
meters from the earth electrode
3 1048766 Terminal lsquoCrsquo is connected to the current spike (red conductor) at a distance of 20 meters
from the earth electrode
Earth Electrode Resistance Measurement Method (Figure 86)
This test must be repeated at least three times to ensure that the reading is not affected by interacting
earthing regions
i Record the first reading (Z1) Example Z1 = 10 Ω
ii Move the voltage spike to a distance of 6 meters from the original position Record the second
reading (Z2 ) Example Z2 = 10 Ω
iii Move the voltage spike to a distance of 6 meters from the original position Record the third
reading (Z3) Example Z3 = 10 Ω
66 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Residual Current Device Testi Ensure that the residual current device (RCD) trips within the set time on the occurrence of current
leakage to earth
ii Test Equipment ndash RCD Tester RCCB Tester
iii Test Method 1
1 1048766 Use the Trip Test Button
2 1048766 Press the trip button found on the RCD to determine if it trips or otherwise This test would
not be able to determine the sensitivity of the RCD nor the time taken for it to trip
iv Test Method 2
i 1048766 Use a RCD Tester
ii This equipment is equipped with a 13A plug which can be connected to a 13A socket outlet
Select the RCD sensitivity to be the same as the sensitivity of the RCD to be tested to
determine if the RCD can trip The time to trip shall not exceed 40 mS
iii 1048766 Test method ndash
a) Position the selection switch in accordance with the sensitivity of the RCD used
Example 100 mA 01 A
b) Position the operations switch to lsquoNo Triprsquo (frac12 Rated mA = 50) connect the 3 pin plug to
the 13A socket outlet
67 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
c) Switch on the 13A socket outlet ndash ensure that the P-N and P-E lights light up
This shows that the polarity is correct (Note if both the lights as above do not light up the test cannot
be continued)
d) Press the test button ndash the reading shows less than 200 mS and simultaneously the lsquotestrsquo light lights
up and the P-N and P-E lights do not light up At that instant the RCD will not trip
e) Move the selection switch to 180o (+ve wave) ndash repeat steps (d) and (e) Move the operations
switch to lsquoTriprsquo (Rated mA = 100)
g) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200mS
h) Move the selection switch to 0o (-ve wave)
i) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
j) The above test is repeated until a near correct reading is obtained
k) Record the test results
l) Change the operations switch to lsquoFast Triprsquo and press the test button ndash RCD will trip within a
time not exceeding 40 millisecond
m) Repeat a number of times at 0o or 180o
On completion of a wiring installation a number of tests on the installation have to be conducted to
ascertain that the wiring circuits and connected appliances are safe for use Prior to carrying out the
tests an inspection has to be done the following tests shall be conducted
i Continuity Test
ii Insulation Resistance Test
iii Polarity Test
iv Earth Electrode Resistance test and
v Residual Current Device Test
821 Continuity Test
There are 3 main types of continuity tests for the final circuits-
i Protection Conductor Continuity Test
ii Final Ring Circuit Conductor Continuity Test
68 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
iii Live and Neutral Conductor Continuity Test
a) Protection Conductor Continuity Test
bull To ascertain that all protection conductors are connected in the correct and effective manner
bull Test equipment ndash Multimeter (Ohm range) or Ohm meter
bull Test Method
1 1048766 Ensure that the main switch RCD and MCB are open circuited (switched off) and all loads are
disconnected
2 1048766 Connected the test leads as in the Figure 81
3 1048766 The meter reading shall be less than 1 Ω
Final Ring Circuit Conductor Continuity Test
bull To ensure that all conductors around the ring circuit have continuity
bull Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
bull Test Method
1 1048766 Disconnect both the supply source live conductors from the MCB the neutral conductor
from the neutral terminals and the earth conductor from the earth terminal in the distribution
fuse box
2 1048766 Connect the test leads as in the Figure 82 (EE)
3 1048766 Repeat the procedure for (L-L) and (N-N)
4 1048766 The meter reading value shall be less than 1 ohm Figure 82 - Final Ring Circuit Conductor
Continuity Test Ohm Meter
Disconnect both the supply source cables from mcbfuse
Take readings at earth conductors of both sources and note resistance readings
Live and Neutral Conductor Continuity Test
1 To ensure that each conductor in the circuit has continuity
2 Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
3 Test Method
1 1048766 Switch off the Main switch RCD and MCB
2 1048766 Disconnect all loads
3 1048766 Switch on all switches in the circuit
4 1048766 Disconnect the fusesfinal circuit breakers and close the circuit
5 1048766 Carry out the test as shown in Figure 83
6 1048766 The meter reading value shall be less than 1 ohm Figure 83 - Live and Neutral
Conductor Continuity Test Ohm Meter
Insulation Resistance Test
69 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
i Ensure that there is no leakage current between phase conductors phase and neutral conductors and
phase conductor and earth
ii Test the strength of the cable insulation
iii Test Equipment ndash Insulation Resistance Tester Operating voltage is 250VDC or 500VDC
iv Test Method
1 1048766 Switch off main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in the Table below
5 1048766 Meter reading value shall be less than 1 Megaohm
Polarity Test
i Ensure that each fuse or single pole control and protection device is connected only in the phase
conductor
ii Intermediate contact of Edison screw lamp holder is connected to the phase conductor
iii Ensure that phase neutral and earth conductors at socket outlets are connected at the correct
terminals
iv Test Equipment ndash Multimeter (Ohm range) or Ohm meter
v Test Method
1 1048766 Switch off Main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in Figure 85
5 1048766 Test switches and single phase control devices at the phase conductors
6 1048766 Test socket outlet connection sources
7 1048766 Test Edison screw lamp holder connections
8 1048766 Meter reading value shall be less than 1 Ω
Earth Electrode Resistance Test
i To test the earth electrode resistance
70 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
ii To ascertain the suitability of the location of the electrode
iii To ensure that the electrode is not buried within the resistance area of another electrode
iv Test equipment ndash Earth Resistance Tester
v Test method -
1 1048766 Terminal rsquoErsquo is connected to the electrode to be tested (green conductor)
2 1048766 Terminal lsquoPrsquo is connected to the potential spike (yellow conductor) at a distance of 10
meters from the earth electrode
3 1048766 Terminal lsquoCrsquo is connected to the current spike (red conductor) at a distance of 20 meters
from the earth electrode E P C Electrode 10 meter 10 meter
Figure 86 ndash Earth Electrode Resistance Measurement Test Equipment
Earth Electrode Resistance Measurement Method (Figure 86)
This test must be repeated at least three times to ensure that the reading is not affected by interacting
earthing regions
i Record the first reading (Z1) Example Z1 = 10 Ω
ii Move the voltage spike to a distance of 6 meters from the original position Record the second
reading (Z2) Example Z2 = 10 Ω
iii Move the voltage spike to a distance of 6 meters from the original position Record the third
reading (Z3)
Example Z3 = 10 Ω
Residual Current Device Test
71 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
i Ensure that the residual current device (RCD) trips within the set time on the occurrence of current
leakage to earth
ii Test Equipment ndash RCD Tester RCCB Tester
iii Test Method 1
1 1048766 Use the Trip Test Button
2 1048766 Press the trip button found on the RCD to determine if it trips or otherwise This test would
not be able to determine the sensitivity of the RCD nor the time taken for it to trip
iv Test Method 2
1048766 Use a RCD Tester
This equipment is equipped with a 13A plug which can be connected to a 13A socket outlet Select the
RCD sensitivity to be the same as the sensitivity of the RCD to be tested to determine if the RCD can
trip The time to trip shall not exceed 40 mS
1048766 Test method ndash
a) Position the selection switch in accordance with the sensitivity of the RCD used
Example 100 mA 01 A
b) Position the operations switch to lsquoNo Triprsquo (frac12 Rated mA = 50) connect the 3 pin plug to
the 13A socket outlet
c) Switch on the 13A socket outlet ndash ensure that the P-N and P-E lights light up This shows that
the polarity is correct (Note if both the lights as above do not light up the test cannot be
continued)
d) Press the test button ndash the reading shows less than 200 millisecond and simultaneously the
lsquotestrsquo light lights up and the P-N and P-E lights do not light up At that instant the RCD will
not trip
e) Move the selection switch to 180o (+ve wave) ndash repeat steps (d) and (e) = 100)
f) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
g) Move the selection switch to 0o (-ve wave)
h) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
i) The above test is repeated until a near correct reading is obtained
j) Record the test results
k) Change the operations switch to lsquoFast Triprsquo and press the test button ndash RCD will trip within a
time not exceeding 40 mS
l) Repeat a number of times at 0o or 180o
72 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 9 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (DC)
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
73 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Start stop button 240Vac 5A 2
9 Filament lamp (Bulb ) 240Vac 40W 3
10 Overload Relay 415V 20A 3
11 Three phase induction motor 5 hp 3
12 Single phase step down transformer 2500VA 1
13 Single core PVC insulated Cable 1mm 2 As required
14 Single core PVC insulated Cable 25mm 2 As required
15 DIN rail 35 mm As required
16 PVC type Cable tray 50 mm x 50 mm As required
17 Cable ties 4 ldquo As required
18 Flexible wires 05 mm As required
19 PVC Connectors 5 A amp 20 A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the schematic
diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a optional exercise
i Simple DOL starter
ii Forward reverse DOL starter
iii Forward Reverse Dahlander motor
iv Three motors operated in sequence by DOL starter operated by manual push
button or time delay relay
74 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
a One loop per-cycle
b Continuous operation in a loop
c optional circuit design to represent the same task
v Only one out of three motors to be operated at a time (quiz)
4 Test the functionality of completed project
LESSON 10 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (AC)
75 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 1
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Lamp point 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
76 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
11 Overload Relay 415V 20A 3
12 Three phase induction
motor
5 hp 3
13 Single core PVC insulated
Cable
1mm 2 As required
14 Single core PVC insulated
Cable
25mm 2 As required
15 DIN rail 35 mm As required
16 PVC type Cable tray 50 mm x 50 mm As required
17 Cable ties 4 ldquo As required
18 Flexible wires 05 mm As required
19 PVC Connectors 5 A amp 20 A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the
schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram optional exercise
4 Simple DOL starter
5 Forward reverse DOL starter
6 Test the functionality of completed project
77 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 1
78 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
cm
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Indicating light 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
11 Overload Relay 415V 20A 3
12 Three phase induction motor 5 hp 3
13 Single phase step down
transformer
2500VA 1
14 Single core PVC insulated
Cable
1mm 2 As required
15 Single core PVC insulated
Cable
25mm 2 As required
16 DIN rail 35 mm As required
17 PVC type Cable tray 50 mm x 50 mm As required
18 Cable ties 4 ldquo As required
19 Flexible wires 05 mm As required
20 PVC Connectors 5 A amp 20 A 240 V As required
21 Single pole MCB 6A 240 V 1
22 Single pole MCB 2A 240 V 1
23 Triple pole MCB 20A 415 V 1
24 Mounting board 30 cm x 40 cm x 3
cm
1
25 Relay cw 11 pin socket 10 A 240 Vac 2
26 Time delay relay 10 A 240 Vac 3
27 Triple pole Contactor 20A 240Vac 3
28 Batten type Lamp holder 240Vac 10 A 3
29 Start stop button 240Vac 10A 2
30 Indicating light (Bulb ) 240Vac 25W 3
31 Overload Relay 415V 20A 1
32 Three phase dahlander type
induction motor
5 hp 1
33 Single phase step down
transformer
24024Vac
2500VA
1
79 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
34 Single core PVC insulated
Cable
1mm 2 As required
35 Single core PVC insulated
Cable
25mm 2 As required
36 DIN rail 35 mm As required
37 PVC type Cable tray 50 mm x 50 mm As required
38 Cable ties 4 ldquo As required
39 Flexible wires 075 mm As required
40 PVC Connectors 5 A amp 20 A 240 V As required
41 Terminal block 20A 240Vac As required
Procedures
5 Identify each component according to specification and quantity required from the schematic
diagram attached
6 Test the functionality of each component by using multi-meter or power supply whichever
applicable
7 Wire component according to circuit diagram
8 Three motors operated in sequence by DOL starter operated by manual push button or time
delay relay
a One loop per-cycle
b Continuous operation in a loop
c optional circuit design to represent the same task
d Only one out of three motors to be operated at a time (quiz)
9 Test the functionality of completed project
80 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
BASIC DESIGN INDUSTRIAL MOTOR CONTROL (SEQUENCE CONTROL)
THREE PHASE INDUCTION MOTOR OPERATED IN SEQUENCE BY DIRECT ON LINE
STARTER
LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
81 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
82 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Lcd lamp indicator 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
11 Overload Relay 415V 20A 3
12 Three phase induction motor 5 hp 3
13 Single phase step down transformer 2500VA 1
14 Single core PVC insulated Cable 1mm 2 As required
15 Single core PVC insulated Cable 25mm 2 As required
16 DIN rail 35 mm As required
17 PVC type Cable tray 50 mm x 50 mm As required
18 Cable ties 4 ldquo As required
19 Flexible wires 1 mm Oslash As required
20 PVC Terminal block 10A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the schematic
diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a optional exercise
i Forward Reverse dahlander motor
4 Test the functionality of completed project
83 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
THREE PHASE DAHLANDER TYPE INDUCTION MOTOR OPERATED FORWARD AND
REVERSE OPERATION BY DIRECT ON LINE STARTER
84 ndash 99EASYTECH ENTERPRISE
LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
Introduction
If a motors windings are connected in the star configuration any two phases will be in series across
the supply and hence the line current will be smaller(by 577) than if the windings were connected in
the delta arrangement
Hence larger-type motors with heavy starting currents are first connected in star and then when the
starting currents fall in delta This of course means that all six of the ends of the windings must be
brought to terminations outside the casing (Fig 833)
EZTECH
EZTECH ELECTRICAL INSTALLATION GUIDE
The automatic version of this starter incorporates a timing relay which automatically changes the
connections from star to delta Figs 834 and 835 show the wiring and schematic diagrams for a star
delta starter
Objectives
1 Identify component and the specification
2 Design forward reverse star delta starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
2 ndash 99EASYTECH ENTERPRISE
REV -C
LEGENDMCCB Moulded Case Circuit BreakerTOR Thermal Over Load RelayFOW-C Mains Forward ContactorREV-C Mains Reverse ContactorDC Delta ContactorSC Star ContactorS-SW Mains Selector Switch
SC
V2
W2
U2
DC
V1
W1
U1
TOR
TOR
FOW-C
30A MCCB
TOR
MAIN CIRCUIT FORWARD REVERSE STAR DELTA
RYBN S
-SW
3 PHASEINDUCTION MOTOR
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Relay 10 A 240V 3
5 Triple pole Contactor
6 cw NO NC auxiliary contact
240Vac 20 A 4
7 Overload Relay 415 V 1
8 LED indicator 240vac 5 A 4
9 Start stop button 240Vac 5A 2
10 DIN rail 35 mm As required
11 Flexible wires 1 mm As required
12 Single core PVC insulated
wire
25 mm As required
13 Terminal block 20 A As required
14 Squirrel cage motor 5kW 1
15 5 pin plug and socket 415V 20A 1
16 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
3 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
a Manual star delta
b Manual Forward reverse star delta starter
c Automatic star delta starter
d Automatic Forward reverse star delta starter
4 Test the functionality of completed project
4 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
Objectives
1 Identify component and the specification
2 Design auto transformer starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
5 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Autotransformer starter is used to start a 3 phase induction motor that has a rating between 10 to 15 hp
6 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Autotransformer set 10Kw 415 V 50 Hz 1
5 Triple pole Contactor 240Vac 4
6 Batten type Lamp holder 240 Vac 105 A 4
7 Start stop button 240Vac 10A 4
8 Filament lamp (Bulb ) 240Vac 40W 4
9 DIN rail 35 mm As required
10 Flexible wires 1 mm As required
7 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
11 Single core PVC insulated
wire
25 mm As required
12 Terminal block 20 A As required
13 Squirrel cage motor 10kW 1
14 5 pin plug and socket 415V 20A 1
15 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a open transient autotransformer starter
b close transient autotransformer starter
c Forward reverse autotransformer starter
4 Test the functionality of completed project
8 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
Objectives
1 Identify component and the specification
2 Design rotor resistance starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
9 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Rotor Resistor set 10kW 1
5 Triple pole Contactor 240Vac 20A 4
6 Indicating light 240vac 5 A 4
7 Start stop push button 240Vac 5A 4
8 DIN rail 35 mm As required
9 Flexible wires 1 mm 2 As required
10 Single core PVC insulated wire 25 mm 2 As required
11 Terminal block 20 A As required
12 Slip Ring motor 10kW 1
13 5 pin round 3 phase socket 415V 20A 1
14 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
10 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
4 Test the functionality of completed project
a Dead circuit test b Life circuit test
5 Measure starting and running Amps
LESSON 16
TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
An installation in general will suffer damage
Damage usually occurs on the electric motor control as follows
1 Damage to the main circuit
2 Damage to the control circuit
The cause of the damage
i Overcurrent overload short circuit
ii Leakage current to ground
iii Equipment malfunction
iv The main control circuit
a Trip of main circuit protection devices fire
b Defect of motor terminal such as short circuit fire loose
v The control circuit is not functioning -
a contactor relay relay time overload relay does not work damaged burned
b Loose cable connection disconnected
Detecting and Repairing Damage
Examples of damage are as follows
i Motor does not work
ii Motor function and overload relay trips
iii Motor function but only partially functional control circuit
Methods of detecting damage
Among the known methods necessary to detect damage are as follows
1 Turn off the electricity at the main switch (main switch) in order to avoid any danger during the
work carried out to detect damage
2 Check all the protective gear that controls the motor control main circuit
11 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
3 Make sure the damage function control circuit
4 Check the control circuit according to the schematic circuit diagram of the motor control
5 Check the operation of the control circuit
Note
Use wiring that has been installed on the SYSTEM OF MOTOR CONTROL BOARD by Forward
Reverse control circuit for Star Delta to test and look for damage
SELF-ASSESSMENT QUESTIONS
1 (a) Explain what is meant by the term lsquoback emfrsquo in a motor
(b) Outline the basic differences between series shunt and compound wound dc motors
2 (a) With the aid of diagrams explain how the speed of series shunt and compound-wound motors
may be controlled
(b) A 440V dc shunt-wound motor has a field resistance of 200R and an armature resistance of 06 R
When its speed is 20 rev d second the current drawn from the supply is 122A Calculate its back
emf at this speed If the speed were decreased to 19 revssecond the field flux remaining unchanged
calculate the new back emf and the new armature current
3 A load of 64 kW at 240 V is supplied from the terminals of a shunt-wound dc generator The field
resistance is 180 A Calculate the armature current
4 (a) Explain with the aid of a diagram how a rotating magnetic field may be
(b) What is meant by lsquosynchronous speedrsquo
Calculate the synchronous obtained speed of a 12 pole motor if the supply frequency is 50Hz
5 (a) Explain the action of a synchronous motor
(b) What methods are available to start a synchronous motor Explain with diagrams
6 (a) Explain the action of a cage induction motor
(b) What is meant by the term lsquosliprsquo
Calculate the percentage slip of a six pole induction motor running at 162 revssecond from a 50 Hz
supply
7 Describe with sketches three different ways of starting a single-phase induction motor
12 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
8 Explain with the aid of a sketch the action of a three-phase DOL starter
What are dashpots used for How are remote start and stop buttons connected
9 A I0 kW 240V 50Hz single-phase cage rotor induction motor is 85efficient and has a PF of 068
lagging Calculate the motor current and the value of capacitor required to raise the PF to 093
lagging
10 Calculate the torque developed by an 18 kW four-pole induction motor run at 35 slip from a
50Hz supply
APPENDIX 1
13 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 11
14 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 111
Attachment Reference
httpswwwtlc-directcoukBook621htm
httpwwwstgovmyindexphpms
15 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
37 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
38 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify conduit fitting and the specification
2 Measure and Cut steel conduit according to specified dimension
3 Bend and fabricate conduit at 45 90 according to layout diagram
4 Wire component according to the schematic diagram
5 Test the functionality of the circuit
39 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Conduit Bender Oslash 19 mm ( frac34 ldquo) 1
2 Measuring Tape 3 metre 1
3 Hacksaw frame and blade 30cm 1
4 Conduit cutter 1
5 Pipe Vise 1
6 Pipe Wrench 1
7 Ratchet Dies 20 mm 1
8 Metal trunking 50 mm x 50 mm 1
9 GI conduit 20mm 1
10 End box 20 mm 1
11 Flexible wires 05 mm As required
12 Connectors 5 A As required
13 Single core PVC ins Cable 25 mm 2 As required
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Wire two unit of 13 A socket outlet in radial circuit
3 Wire four unit of 13 A socket outlet in ring circuit
4 Wire one unit DOL starter for air-conditioner point
5 Wire one unit of cooker control unit point
6 Wire one unit of water heater point
7 Test the functionality of each component by using multimeter or power supply whichever
applicable
8 Wire component according to circuit diagram
9 Test the functionality of completed project
Note
Ensure that the rating of protection device and size of wire
K prior to 31 March
2004 (BS 7671)
(formerly)
bare conductor
sleeved at terminations (formerly)
40 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 5 ndashWIRING SYSTEM OF 1 Oslash LIGHTING AND POWER CIRCUIT
POWER CIRCUITSa Radial circuits
Radial circuits are arranged in the same way as item 1 above in lighting layouts in that each socket
outlet is supplied via the previous one
Points to note
1 The number of socket outlets complying with BS 1363 is unlimited for a floor area of up to 50m 2 if
the circuit protection is a 30 A or 32 A cartridge fuse or circuit breaker the cable being 4 mm PVC
copper or 25 mm2 mineral insulated (mi)
2 The number of socket outlets is unlimited for a floor area up to 20 m 2 with any type of circuit
protection of 20 A using 25 mm2 PVC copper cable or 15 mm2 mi
3 The total number of fused spurs is unlimited
b ring final circuits
These circuits are the same as radial circuits except that the final socket outlet is wired back to the
supply position In effect any outlet is supplied from two directions (Fig 152)
Points to note
1 Every twin-socket outlet counts as two single-socket outlets
2 The number of non-fused spurs must not exceed the total number of points on the ring Fig 158
shows seven points on the ring and five spurs
3 The fuse rating of a fused spur box must not exceed 13 A and the current rating of all points supplied
by the fused spur must not exceed 13 A
4 Non-fused spurs must supply no more than one single or one double socket on the ring Fig 158
shows seven points on the ring and five spurs rating of all points supplied by the fused spur must not
exceed 13 A or one stationary appliance
CapacityMain conductor size
copper (mm2)
Earth conductor
size (mm2)
Circuit breaker
capacity (A)
Up to 600 W 15 15 6
600ndash1200 W 1525 15 10
1200ndash1800 W 254 25 16
41 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Ring circuit
(floor area 100 m2)25 15 3032
A2 radial circuit
(floor area 75 m2)40 25 3032
A3 radial circuit
(floor area 50 m2)25 15 20
Air conditioner (15 tonne) 60 60 3032
Cooker 60 60 3032
Water heater 40 40 20
Objectives
1 Identify component and the specification
2 Wire component according to the schematic diagram
3 Test the functionality of the circuit
42 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board Perforated 1
2 Cut out fuse and neutral link 60A 240V 1each
3 kWh meter 240V 40A 1
4 Switched Socket outlet 13A 240Vac 4
5 Single pole two way switch cw switch
box
5A 240Vac 2
6 RCCB ELCB 63 A Tripping current 100mA
415 Vac
1
7 3 pin plug 240Vac 13A 4
8 Single pole MCB 20 A 2
9 Single pole MCB 6A 1
10 Single pole MCB 20A 2
11 DOL starter 240Vac 2
12 1 phase induction motor 2hp 240 Vac 1
13 Self tapping Wood screw As required
14 DIN rail Stainless steel allum35 mm As required
15 PVC pipe 20mm dia As required
16 End box 20 mm dia 4
17 Flexible wires 05 mm 2 As required
18 Connectors 5 A As required
Procedures
43 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
4 Test the functionality of completed project
LESSON 6 ndash WIRING SYSTEM OF 3 Oslash DISTRIBUTION BOARD
Introduction
44 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
45 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
46 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
47 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
48 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify each component and the specification
2 Wire component according to the schematic diagram given
3 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting Board 450 x 600 mm Perforated metal 1
2 5 pin round socket and plug 415V ac 32A 1
3 Cut out fuse 60 A 3
4 Neutral link 1
5 kWatt hour meter 415V 60A 1
6 ELCB RCCB 3P+N In=63A415 Vac I trip= 300mA 1
7 ELCB RCCB 3P+N In=63A415 Vac I trip= 30mA 1
8 Single pole MCB 6A 240 V 3
9 Single pole MCB 20A 240 V 3
10 DOL starter 20 A 240Vac 2
11 Socket outlet 15 A 240 Vac 1
12 Switched Socket outlet 13 A 240 Vac 3
13 Led indicating light 5A 240 Vac 3
14 Single pole 4 gang 1 way switch 5A 240 Vac 2
15 Single pole 2 way switch 5A 240 Vac 2
16 1 phase induction motor 1 kW 240Vac 1
17 Metal trunking 30 mm x30 mm As required
18 Self tapping Wood screw 4 mm x 20 mm As required
19 DIN rail 25 mm x 1mm
20 GI steel rigid conduit 20mm As required
21 Flexible conduit 20mm As required
22 End box 20 mm 4
23 Flexible wires 05 mm 2 As required
24 Single core PVC insulated wire 15 mm 2 As required
25 Single core PVC insulated wires 25 mm 2 As required
26 Terminal block 10 A As required
Procedures
49 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify each components and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
4 Test the functionality of completed project
1 dead circuit test
2 life circuit
Note Proper earthing should be made
50 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 7 ndash WIRING SYSTEM OF THREE PHASE LIGHTING AND POWER CIRCUIT
51 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
52 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify component and the specification
2 Wire component according to the schematic diagram
3 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting bay Board Perforated metal 180 cm x 180 cm 1
2 k Watt hour meter 415V 60A 1
3 MCCB 415V 60A
4 ELCB RCCB In=60A415 Vac I trip=30mA 1
5 5 pin round Socket and
plug
415Vac 32A 4
6 Single pole MCB 6A 1
7 Triple pole MCB 20A 2
8 Triple pole Main switch 60A 1
9 DOL starter 240Vac 2
10 3 phase induction motor 2hp 415 Vac 1
11 1 phase induction motor 1
12 Metal trunking 30 mm x30 mm As required
13 Self tapping Wood screw 4 mm x 20 mm As required
14 DIN rail 25 mm x 1mm
15 GI steel rigid conduit 20mm As required
16 Flexible conduit 20mm As required
17 End box 20 mm 4
18 Flexible wires 05 mm As required
19 Connectors 10 A As required
Procedures
1 Identify each components and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
4 Test the functionality of completed project
1 dead circuit 2 life circuit test
5 Record the current drawn by the load as connected in star and delta
Note Proper earthing should be made
53 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 8 INSPECTION AND TESTING OF ELECTRICAL INSTALLATION
On completion of a wiring installation a number of tests on the installation have to be conducted to
ascertain that the wiring circuits and connected appliances are safe for use Prior to carrying out the
tests an inspection has to be done The results of the inspectionsupervision and test have to be
presented in Form G (as in Appendix IV) and Form H (as in Appendix V)
To have the test certification as in Form H the following tests shall be conducted
i Continuity Test
ii Insulation Resistance Test
iii Polarity Test
iv Earth Electrode Resistance test and
v Residual Current Device Test
1 Continuity Test
There are 3 main types of continuity tests for the final circuits-
i Protection Conductor Continuity Test
ii Final Ring Circuit Conductor Continuity Test
iii Live and Neutral Conductor Continuity Test
a) Protection Conductor Continuity Test
bull To ascertain that all protection conductors are connected in the correct and effective manner
bull Test equipment ndash Multimeter (Ohm range) or Ohm meter
54 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
bull Test Method
1 1048766 Ensure that the main switch RCD and MCB are open circuited (switched off) and all loads
are disconnected
2 1048766 Connected the test leads as in the Figure 81 The meter reading shall be less than 1 Ω
55 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Final Ring Circuit Conductor Continuity Test
bull To ensure that all conductors around the ring circuit have continuity
bull Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
bull Test Method
1 1048766 Disconnect both the supply source live conductors from the MCB the neutral conductor
from the neutral terminals and the earth conductor from the earth terminal in the distribution
fuse box
2 1048766 Connect the test leads as in the Figure 82 (EE)
3 1048766 Repeat the procedure for (L-L) and (N-N)
4 1048766 The meter reading value shall be less than 1 ohm
56 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Live and Neutral Conductor Continuity Test
a To ensure that each conductor in the circuit has continuity
b Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
2 Test Method
1 1048766 Switch off the Main switch RCD and MCB
2 1048766 Disconnect all loads
3 1048766 Switch on all switches in the circuit
4 1048766 Disconnect the fusesfinal circuit breakers and close the circuit
5 1048766 Carry out the test as shown in Figure 83
6 1048766 The meter reading value shall be less than 1Ω
57 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
58 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
CONTINUITY TEST
Insulation Resistance Test
i Ensure that there is no leakage current between phase conductors phase and neutral conductors and
phase conductor and earth
ii Test the strength of the cable insulation
iii Test Equipment ndash Insulation Resistance Tester operating voltage is 250VDC or 500VDC
iv Test Method
1 1048766 Switch off main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
59 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
4 1048766 Carry out test as in the Table below
5 1048766 Meter reading value shall be less than 1 Megaohm
60 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
61 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Insulation resitance test
62 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
INSULATION RESISTANCE TEST BETWEEN CONDUCTORS AND OPPOSITE POLARITY
Polarity Testi Ensure that each fuse or single pole control and protection device is connected only in the phase
conductor
ii Intermediate contact of Edison screw lamp holder is connected to the phase conductor
iii Ensure that phase neutral and earth conductors at socket outlets are connected at the correct
terminals
iv Test Equipment ndash Multimeter (Ohm range) or Ohm meter
v Test Method
1 1048766 Switch off Main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in Figure 85
63 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
5 1048766 Test switches and single phase control devices at the phase conductors
6 1048766 Test socket outlet connection sources
7 1048766 Test Edison screw lamp holder connections
8 1048766 Meter reading value shall be less than 1 Ω
64 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Polarity test
65 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Earth Electrode Resistance Testi To test the earth electrode resistance
ii To ascertain the suitability of the location of the electrode
iii To ensure that the electrode is not buried within the resistance area of another electrode
iv Test equipment ndash Earth Resistance Tester
v Test method -
1 1048766 Terminal rsquoErsquo is connected to the electrode to be tested (green conductor)
2 1048766 Terminal lsquoPrsquo is connected to the potential spike (yellow conductor) at a distance of 10
meters from the earth electrode
3 1048766 Terminal lsquoCrsquo is connected to the current spike (red conductor) at a distance of 20 meters
from the earth electrode
Earth Electrode Resistance Measurement Method (Figure 86)
This test must be repeated at least three times to ensure that the reading is not affected by interacting
earthing regions
i Record the first reading (Z1) Example Z1 = 10 Ω
ii Move the voltage spike to a distance of 6 meters from the original position Record the second
reading (Z2 ) Example Z2 = 10 Ω
iii Move the voltage spike to a distance of 6 meters from the original position Record the third
reading (Z3) Example Z3 = 10 Ω
66 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Residual Current Device Testi Ensure that the residual current device (RCD) trips within the set time on the occurrence of current
leakage to earth
ii Test Equipment ndash RCD Tester RCCB Tester
iii Test Method 1
1 1048766 Use the Trip Test Button
2 1048766 Press the trip button found on the RCD to determine if it trips or otherwise This test would
not be able to determine the sensitivity of the RCD nor the time taken for it to trip
iv Test Method 2
i 1048766 Use a RCD Tester
ii This equipment is equipped with a 13A plug which can be connected to a 13A socket outlet
Select the RCD sensitivity to be the same as the sensitivity of the RCD to be tested to
determine if the RCD can trip The time to trip shall not exceed 40 mS
iii 1048766 Test method ndash
a) Position the selection switch in accordance with the sensitivity of the RCD used
Example 100 mA 01 A
b) Position the operations switch to lsquoNo Triprsquo (frac12 Rated mA = 50) connect the 3 pin plug to
the 13A socket outlet
67 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
c) Switch on the 13A socket outlet ndash ensure that the P-N and P-E lights light up
This shows that the polarity is correct (Note if both the lights as above do not light up the test cannot
be continued)
d) Press the test button ndash the reading shows less than 200 mS and simultaneously the lsquotestrsquo light lights
up and the P-N and P-E lights do not light up At that instant the RCD will not trip
e) Move the selection switch to 180o (+ve wave) ndash repeat steps (d) and (e) Move the operations
switch to lsquoTriprsquo (Rated mA = 100)
g) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200mS
h) Move the selection switch to 0o (-ve wave)
i) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
j) The above test is repeated until a near correct reading is obtained
k) Record the test results
l) Change the operations switch to lsquoFast Triprsquo and press the test button ndash RCD will trip within a
time not exceeding 40 millisecond
m) Repeat a number of times at 0o or 180o
On completion of a wiring installation a number of tests on the installation have to be conducted to
ascertain that the wiring circuits and connected appliances are safe for use Prior to carrying out the
tests an inspection has to be done the following tests shall be conducted
i Continuity Test
ii Insulation Resistance Test
iii Polarity Test
iv Earth Electrode Resistance test and
v Residual Current Device Test
821 Continuity Test
There are 3 main types of continuity tests for the final circuits-
i Protection Conductor Continuity Test
ii Final Ring Circuit Conductor Continuity Test
68 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
iii Live and Neutral Conductor Continuity Test
a) Protection Conductor Continuity Test
bull To ascertain that all protection conductors are connected in the correct and effective manner
bull Test equipment ndash Multimeter (Ohm range) or Ohm meter
bull Test Method
1 1048766 Ensure that the main switch RCD and MCB are open circuited (switched off) and all loads are
disconnected
2 1048766 Connected the test leads as in the Figure 81
3 1048766 The meter reading shall be less than 1 Ω
Final Ring Circuit Conductor Continuity Test
bull To ensure that all conductors around the ring circuit have continuity
bull Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
bull Test Method
1 1048766 Disconnect both the supply source live conductors from the MCB the neutral conductor
from the neutral terminals and the earth conductor from the earth terminal in the distribution
fuse box
2 1048766 Connect the test leads as in the Figure 82 (EE)
3 1048766 Repeat the procedure for (L-L) and (N-N)
4 1048766 The meter reading value shall be less than 1 ohm Figure 82 - Final Ring Circuit Conductor
Continuity Test Ohm Meter
Disconnect both the supply source cables from mcbfuse
Take readings at earth conductors of both sources and note resistance readings
Live and Neutral Conductor Continuity Test
1 To ensure that each conductor in the circuit has continuity
2 Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
3 Test Method
1 1048766 Switch off the Main switch RCD and MCB
2 1048766 Disconnect all loads
3 1048766 Switch on all switches in the circuit
4 1048766 Disconnect the fusesfinal circuit breakers and close the circuit
5 1048766 Carry out the test as shown in Figure 83
6 1048766 The meter reading value shall be less than 1 ohm Figure 83 - Live and Neutral
Conductor Continuity Test Ohm Meter
Insulation Resistance Test
69 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
i Ensure that there is no leakage current between phase conductors phase and neutral conductors and
phase conductor and earth
ii Test the strength of the cable insulation
iii Test Equipment ndash Insulation Resistance Tester Operating voltage is 250VDC or 500VDC
iv Test Method
1 1048766 Switch off main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in the Table below
5 1048766 Meter reading value shall be less than 1 Megaohm
Polarity Test
i Ensure that each fuse or single pole control and protection device is connected only in the phase
conductor
ii Intermediate contact of Edison screw lamp holder is connected to the phase conductor
iii Ensure that phase neutral and earth conductors at socket outlets are connected at the correct
terminals
iv Test Equipment ndash Multimeter (Ohm range) or Ohm meter
v Test Method
1 1048766 Switch off Main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in Figure 85
5 1048766 Test switches and single phase control devices at the phase conductors
6 1048766 Test socket outlet connection sources
7 1048766 Test Edison screw lamp holder connections
8 1048766 Meter reading value shall be less than 1 Ω
Earth Electrode Resistance Test
i To test the earth electrode resistance
70 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
ii To ascertain the suitability of the location of the electrode
iii To ensure that the electrode is not buried within the resistance area of another electrode
iv Test equipment ndash Earth Resistance Tester
v Test method -
1 1048766 Terminal rsquoErsquo is connected to the electrode to be tested (green conductor)
2 1048766 Terminal lsquoPrsquo is connected to the potential spike (yellow conductor) at a distance of 10
meters from the earth electrode
3 1048766 Terminal lsquoCrsquo is connected to the current spike (red conductor) at a distance of 20 meters
from the earth electrode E P C Electrode 10 meter 10 meter
Figure 86 ndash Earth Electrode Resistance Measurement Test Equipment
Earth Electrode Resistance Measurement Method (Figure 86)
This test must be repeated at least three times to ensure that the reading is not affected by interacting
earthing regions
i Record the first reading (Z1) Example Z1 = 10 Ω
ii Move the voltage spike to a distance of 6 meters from the original position Record the second
reading (Z2) Example Z2 = 10 Ω
iii Move the voltage spike to a distance of 6 meters from the original position Record the third
reading (Z3)
Example Z3 = 10 Ω
Residual Current Device Test
71 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
i Ensure that the residual current device (RCD) trips within the set time on the occurrence of current
leakage to earth
ii Test Equipment ndash RCD Tester RCCB Tester
iii Test Method 1
1 1048766 Use the Trip Test Button
2 1048766 Press the trip button found on the RCD to determine if it trips or otherwise This test would
not be able to determine the sensitivity of the RCD nor the time taken for it to trip
iv Test Method 2
1048766 Use a RCD Tester
This equipment is equipped with a 13A plug which can be connected to a 13A socket outlet Select the
RCD sensitivity to be the same as the sensitivity of the RCD to be tested to determine if the RCD can
trip The time to trip shall not exceed 40 mS
1048766 Test method ndash
a) Position the selection switch in accordance with the sensitivity of the RCD used
Example 100 mA 01 A
b) Position the operations switch to lsquoNo Triprsquo (frac12 Rated mA = 50) connect the 3 pin plug to
the 13A socket outlet
c) Switch on the 13A socket outlet ndash ensure that the P-N and P-E lights light up This shows that
the polarity is correct (Note if both the lights as above do not light up the test cannot be
continued)
d) Press the test button ndash the reading shows less than 200 millisecond and simultaneously the
lsquotestrsquo light lights up and the P-N and P-E lights do not light up At that instant the RCD will
not trip
e) Move the selection switch to 180o (+ve wave) ndash repeat steps (d) and (e) = 100)
f) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
g) Move the selection switch to 0o (-ve wave)
h) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
i) The above test is repeated until a near correct reading is obtained
j) Record the test results
k) Change the operations switch to lsquoFast Triprsquo and press the test button ndash RCD will trip within a
time not exceeding 40 mS
l) Repeat a number of times at 0o or 180o
72 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 9 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (DC)
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
73 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Start stop button 240Vac 5A 2
9 Filament lamp (Bulb ) 240Vac 40W 3
10 Overload Relay 415V 20A 3
11 Three phase induction motor 5 hp 3
12 Single phase step down transformer 2500VA 1
13 Single core PVC insulated Cable 1mm 2 As required
14 Single core PVC insulated Cable 25mm 2 As required
15 DIN rail 35 mm As required
16 PVC type Cable tray 50 mm x 50 mm As required
17 Cable ties 4 ldquo As required
18 Flexible wires 05 mm As required
19 PVC Connectors 5 A amp 20 A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the schematic
diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a optional exercise
i Simple DOL starter
ii Forward reverse DOL starter
iii Forward Reverse Dahlander motor
iv Three motors operated in sequence by DOL starter operated by manual push
button or time delay relay
74 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
a One loop per-cycle
b Continuous operation in a loop
c optional circuit design to represent the same task
v Only one out of three motors to be operated at a time (quiz)
4 Test the functionality of completed project
LESSON 10 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (AC)
75 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 1
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Lamp point 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
76 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
11 Overload Relay 415V 20A 3
12 Three phase induction
motor
5 hp 3
13 Single core PVC insulated
Cable
1mm 2 As required
14 Single core PVC insulated
Cable
25mm 2 As required
15 DIN rail 35 mm As required
16 PVC type Cable tray 50 mm x 50 mm As required
17 Cable ties 4 ldquo As required
18 Flexible wires 05 mm As required
19 PVC Connectors 5 A amp 20 A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the
schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram optional exercise
4 Simple DOL starter
5 Forward reverse DOL starter
6 Test the functionality of completed project
77 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 1
78 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
cm
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Indicating light 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
11 Overload Relay 415V 20A 3
12 Three phase induction motor 5 hp 3
13 Single phase step down
transformer
2500VA 1
14 Single core PVC insulated
Cable
1mm 2 As required
15 Single core PVC insulated
Cable
25mm 2 As required
16 DIN rail 35 mm As required
17 PVC type Cable tray 50 mm x 50 mm As required
18 Cable ties 4 ldquo As required
19 Flexible wires 05 mm As required
20 PVC Connectors 5 A amp 20 A 240 V As required
21 Single pole MCB 6A 240 V 1
22 Single pole MCB 2A 240 V 1
23 Triple pole MCB 20A 415 V 1
24 Mounting board 30 cm x 40 cm x 3
cm
1
25 Relay cw 11 pin socket 10 A 240 Vac 2
26 Time delay relay 10 A 240 Vac 3
27 Triple pole Contactor 20A 240Vac 3
28 Batten type Lamp holder 240Vac 10 A 3
29 Start stop button 240Vac 10A 2
30 Indicating light (Bulb ) 240Vac 25W 3
31 Overload Relay 415V 20A 1
32 Three phase dahlander type
induction motor
5 hp 1
33 Single phase step down
transformer
24024Vac
2500VA
1
79 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
34 Single core PVC insulated
Cable
1mm 2 As required
35 Single core PVC insulated
Cable
25mm 2 As required
36 DIN rail 35 mm As required
37 PVC type Cable tray 50 mm x 50 mm As required
38 Cable ties 4 ldquo As required
39 Flexible wires 075 mm As required
40 PVC Connectors 5 A amp 20 A 240 V As required
41 Terminal block 20A 240Vac As required
Procedures
5 Identify each component according to specification and quantity required from the schematic
diagram attached
6 Test the functionality of each component by using multi-meter or power supply whichever
applicable
7 Wire component according to circuit diagram
8 Three motors operated in sequence by DOL starter operated by manual push button or time
delay relay
a One loop per-cycle
b Continuous operation in a loop
c optional circuit design to represent the same task
d Only one out of three motors to be operated at a time (quiz)
9 Test the functionality of completed project
80 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
BASIC DESIGN INDUSTRIAL MOTOR CONTROL (SEQUENCE CONTROL)
THREE PHASE INDUCTION MOTOR OPERATED IN SEQUENCE BY DIRECT ON LINE
STARTER
LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
81 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
82 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Lcd lamp indicator 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
11 Overload Relay 415V 20A 3
12 Three phase induction motor 5 hp 3
13 Single phase step down transformer 2500VA 1
14 Single core PVC insulated Cable 1mm 2 As required
15 Single core PVC insulated Cable 25mm 2 As required
16 DIN rail 35 mm As required
17 PVC type Cable tray 50 mm x 50 mm As required
18 Cable ties 4 ldquo As required
19 Flexible wires 1 mm Oslash As required
20 PVC Terminal block 10A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the schematic
diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a optional exercise
i Forward Reverse dahlander motor
4 Test the functionality of completed project
83 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
THREE PHASE DAHLANDER TYPE INDUCTION MOTOR OPERATED FORWARD AND
REVERSE OPERATION BY DIRECT ON LINE STARTER
84 ndash 99EASYTECH ENTERPRISE
LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
Introduction
If a motors windings are connected in the star configuration any two phases will be in series across
the supply and hence the line current will be smaller(by 577) than if the windings were connected in
the delta arrangement
Hence larger-type motors with heavy starting currents are first connected in star and then when the
starting currents fall in delta This of course means that all six of the ends of the windings must be
brought to terminations outside the casing (Fig 833)
EZTECH
EZTECH ELECTRICAL INSTALLATION GUIDE
The automatic version of this starter incorporates a timing relay which automatically changes the
connections from star to delta Figs 834 and 835 show the wiring and schematic diagrams for a star
delta starter
Objectives
1 Identify component and the specification
2 Design forward reverse star delta starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
2 ndash 99EASYTECH ENTERPRISE
REV -C
LEGENDMCCB Moulded Case Circuit BreakerTOR Thermal Over Load RelayFOW-C Mains Forward ContactorREV-C Mains Reverse ContactorDC Delta ContactorSC Star ContactorS-SW Mains Selector Switch
SC
V2
W2
U2
DC
V1
W1
U1
TOR
TOR
FOW-C
30A MCCB
TOR
MAIN CIRCUIT FORWARD REVERSE STAR DELTA
RYBN S
-SW
3 PHASEINDUCTION MOTOR
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Relay 10 A 240V 3
5 Triple pole Contactor
6 cw NO NC auxiliary contact
240Vac 20 A 4
7 Overload Relay 415 V 1
8 LED indicator 240vac 5 A 4
9 Start stop button 240Vac 5A 2
10 DIN rail 35 mm As required
11 Flexible wires 1 mm As required
12 Single core PVC insulated
wire
25 mm As required
13 Terminal block 20 A As required
14 Squirrel cage motor 5kW 1
15 5 pin plug and socket 415V 20A 1
16 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
3 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
a Manual star delta
b Manual Forward reverse star delta starter
c Automatic star delta starter
d Automatic Forward reverse star delta starter
4 Test the functionality of completed project
4 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
Objectives
1 Identify component and the specification
2 Design auto transformer starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
5 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Autotransformer starter is used to start a 3 phase induction motor that has a rating between 10 to 15 hp
6 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Autotransformer set 10Kw 415 V 50 Hz 1
5 Triple pole Contactor 240Vac 4
6 Batten type Lamp holder 240 Vac 105 A 4
7 Start stop button 240Vac 10A 4
8 Filament lamp (Bulb ) 240Vac 40W 4
9 DIN rail 35 mm As required
10 Flexible wires 1 mm As required
7 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
11 Single core PVC insulated
wire
25 mm As required
12 Terminal block 20 A As required
13 Squirrel cage motor 10kW 1
14 5 pin plug and socket 415V 20A 1
15 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a open transient autotransformer starter
b close transient autotransformer starter
c Forward reverse autotransformer starter
4 Test the functionality of completed project
8 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
Objectives
1 Identify component and the specification
2 Design rotor resistance starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
9 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Rotor Resistor set 10kW 1
5 Triple pole Contactor 240Vac 20A 4
6 Indicating light 240vac 5 A 4
7 Start stop push button 240Vac 5A 4
8 DIN rail 35 mm As required
9 Flexible wires 1 mm 2 As required
10 Single core PVC insulated wire 25 mm 2 As required
11 Terminal block 20 A As required
12 Slip Ring motor 10kW 1
13 5 pin round 3 phase socket 415V 20A 1
14 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
10 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
4 Test the functionality of completed project
a Dead circuit test b Life circuit test
5 Measure starting and running Amps
LESSON 16
TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
An installation in general will suffer damage
Damage usually occurs on the electric motor control as follows
1 Damage to the main circuit
2 Damage to the control circuit
The cause of the damage
i Overcurrent overload short circuit
ii Leakage current to ground
iii Equipment malfunction
iv The main control circuit
a Trip of main circuit protection devices fire
b Defect of motor terminal such as short circuit fire loose
v The control circuit is not functioning -
a contactor relay relay time overload relay does not work damaged burned
b Loose cable connection disconnected
Detecting and Repairing Damage
Examples of damage are as follows
i Motor does not work
ii Motor function and overload relay trips
iii Motor function but only partially functional control circuit
Methods of detecting damage
Among the known methods necessary to detect damage are as follows
1 Turn off the electricity at the main switch (main switch) in order to avoid any danger during the
work carried out to detect damage
2 Check all the protective gear that controls the motor control main circuit
11 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
3 Make sure the damage function control circuit
4 Check the control circuit according to the schematic circuit diagram of the motor control
5 Check the operation of the control circuit
Note
Use wiring that has been installed on the SYSTEM OF MOTOR CONTROL BOARD by Forward
Reverse control circuit for Star Delta to test and look for damage
SELF-ASSESSMENT QUESTIONS
1 (a) Explain what is meant by the term lsquoback emfrsquo in a motor
(b) Outline the basic differences between series shunt and compound wound dc motors
2 (a) With the aid of diagrams explain how the speed of series shunt and compound-wound motors
may be controlled
(b) A 440V dc shunt-wound motor has a field resistance of 200R and an armature resistance of 06 R
When its speed is 20 rev d second the current drawn from the supply is 122A Calculate its back
emf at this speed If the speed were decreased to 19 revssecond the field flux remaining unchanged
calculate the new back emf and the new armature current
3 A load of 64 kW at 240 V is supplied from the terminals of a shunt-wound dc generator The field
resistance is 180 A Calculate the armature current
4 (a) Explain with the aid of a diagram how a rotating magnetic field may be
(b) What is meant by lsquosynchronous speedrsquo
Calculate the synchronous obtained speed of a 12 pole motor if the supply frequency is 50Hz
5 (a) Explain the action of a synchronous motor
(b) What methods are available to start a synchronous motor Explain with diagrams
6 (a) Explain the action of a cage induction motor
(b) What is meant by the term lsquosliprsquo
Calculate the percentage slip of a six pole induction motor running at 162 revssecond from a 50 Hz
supply
7 Describe with sketches three different ways of starting a single-phase induction motor
12 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
8 Explain with the aid of a sketch the action of a three-phase DOL starter
What are dashpots used for How are remote start and stop buttons connected
9 A I0 kW 240V 50Hz single-phase cage rotor induction motor is 85efficient and has a PF of 068
lagging Calculate the motor current and the value of capacitor required to raise the PF to 093
lagging
10 Calculate the torque developed by an 18 kW four-pole induction motor run at 35 slip from a
50Hz supply
APPENDIX 1
13 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 11
14 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 111
Attachment Reference
httpswwwtlc-directcoukBook621htm
httpwwwstgovmyindexphpms
15 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
38 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify conduit fitting and the specification
2 Measure and Cut steel conduit according to specified dimension
3 Bend and fabricate conduit at 45 90 according to layout diagram
4 Wire component according to the schematic diagram
5 Test the functionality of the circuit
39 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Conduit Bender Oslash 19 mm ( frac34 ldquo) 1
2 Measuring Tape 3 metre 1
3 Hacksaw frame and blade 30cm 1
4 Conduit cutter 1
5 Pipe Vise 1
6 Pipe Wrench 1
7 Ratchet Dies 20 mm 1
8 Metal trunking 50 mm x 50 mm 1
9 GI conduit 20mm 1
10 End box 20 mm 1
11 Flexible wires 05 mm As required
12 Connectors 5 A As required
13 Single core PVC ins Cable 25 mm 2 As required
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Wire two unit of 13 A socket outlet in radial circuit
3 Wire four unit of 13 A socket outlet in ring circuit
4 Wire one unit DOL starter for air-conditioner point
5 Wire one unit of cooker control unit point
6 Wire one unit of water heater point
7 Test the functionality of each component by using multimeter or power supply whichever
applicable
8 Wire component according to circuit diagram
9 Test the functionality of completed project
Note
Ensure that the rating of protection device and size of wire
K prior to 31 March
2004 (BS 7671)
(formerly)
bare conductor
sleeved at terminations (formerly)
40 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 5 ndashWIRING SYSTEM OF 1 Oslash LIGHTING AND POWER CIRCUIT
POWER CIRCUITSa Radial circuits
Radial circuits are arranged in the same way as item 1 above in lighting layouts in that each socket
outlet is supplied via the previous one
Points to note
1 The number of socket outlets complying with BS 1363 is unlimited for a floor area of up to 50m 2 if
the circuit protection is a 30 A or 32 A cartridge fuse or circuit breaker the cable being 4 mm PVC
copper or 25 mm2 mineral insulated (mi)
2 The number of socket outlets is unlimited for a floor area up to 20 m 2 with any type of circuit
protection of 20 A using 25 mm2 PVC copper cable or 15 mm2 mi
3 The total number of fused spurs is unlimited
b ring final circuits
These circuits are the same as radial circuits except that the final socket outlet is wired back to the
supply position In effect any outlet is supplied from two directions (Fig 152)
Points to note
1 Every twin-socket outlet counts as two single-socket outlets
2 The number of non-fused spurs must not exceed the total number of points on the ring Fig 158
shows seven points on the ring and five spurs
3 The fuse rating of a fused spur box must not exceed 13 A and the current rating of all points supplied
by the fused spur must not exceed 13 A
4 Non-fused spurs must supply no more than one single or one double socket on the ring Fig 158
shows seven points on the ring and five spurs rating of all points supplied by the fused spur must not
exceed 13 A or one stationary appliance
CapacityMain conductor size
copper (mm2)
Earth conductor
size (mm2)
Circuit breaker
capacity (A)
Up to 600 W 15 15 6
600ndash1200 W 1525 15 10
1200ndash1800 W 254 25 16
41 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Ring circuit
(floor area 100 m2)25 15 3032
A2 radial circuit
(floor area 75 m2)40 25 3032
A3 radial circuit
(floor area 50 m2)25 15 20
Air conditioner (15 tonne) 60 60 3032
Cooker 60 60 3032
Water heater 40 40 20
Objectives
1 Identify component and the specification
2 Wire component according to the schematic diagram
3 Test the functionality of the circuit
42 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board Perforated 1
2 Cut out fuse and neutral link 60A 240V 1each
3 kWh meter 240V 40A 1
4 Switched Socket outlet 13A 240Vac 4
5 Single pole two way switch cw switch
box
5A 240Vac 2
6 RCCB ELCB 63 A Tripping current 100mA
415 Vac
1
7 3 pin plug 240Vac 13A 4
8 Single pole MCB 20 A 2
9 Single pole MCB 6A 1
10 Single pole MCB 20A 2
11 DOL starter 240Vac 2
12 1 phase induction motor 2hp 240 Vac 1
13 Self tapping Wood screw As required
14 DIN rail Stainless steel allum35 mm As required
15 PVC pipe 20mm dia As required
16 End box 20 mm dia 4
17 Flexible wires 05 mm 2 As required
18 Connectors 5 A As required
Procedures
43 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
4 Test the functionality of completed project
LESSON 6 ndash WIRING SYSTEM OF 3 Oslash DISTRIBUTION BOARD
Introduction
44 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
45 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
46 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
47 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
48 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify each component and the specification
2 Wire component according to the schematic diagram given
3 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting Board 450 x 600 mm Perforated metal 1
2 5 pin round socket and plug 415V ac 32A 1
3 Cut out fuse 60 A 3
4 Neutral link 1
5 kWatt hour meter 415V 60A 1
6 ELCB RCCB 3P+N In=63A415 Vac I trip= 300mA 1
7 ELCB RCCB 3P+N In=63A415 Vac I trip= 30mA 1
8 Single pole MCB 6A 240 V 3
9 Single pole MCB 20A 240 V 3
10 DOL starter 20 A 240Vac 2
11 Socket outlet 15 A 240 Vac 1
12 Switched Socket outlet 13 A 240 Vac 3
13 Led indicating light 5A 240 Vac 3
14 Single pole 4 gang 1 way switch 5A 240 Vac 2
15 Single pole 2 way switch 5A 240 Vac 2
16 1 phase induction motor 1 kW 240Vac 1
17 Metal trunking 30 mm x30 mm As required
18 Self tapping Wood screw 4 mm x 20 mm As required
19 DIN rail 25 mm x 1mm
20 GI steel rigid conduit 20mm As required
21 Flexible conduit 20mm As required
22 End box 20 mm 4
23 Flexible wires 05 mm 2 As required
24 Single core PVC insulated wire 15 mm 2 As required
25 Single core PVC insulated wires 25 mm 2 As required
26 Terminal block 10 A As required
Procedures
49 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify each components and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
4 Test the functionality of completed project
1 dead circuit test
2 life circuit
Note Proper earthing should be made
50 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 7 ndash WIRING SYSTEM OF THREE PHASE LIGHTING AND POWER CIRCUIT
51 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
52 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify component and the specification
2 Wire component according to the schematic diagram
3 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting bay Board Perforated metal 180 cm x 180 cm 1
2 k Watt hour meter 415V 60A 1
3 MCCB 415V 60A
4 ELCB RCCB In=60A415 Vac I trip=30mA 1
5 5 pin round Socket and
plug
415Vac 32A 4
6 Single pole MCB 6A 1
7 Triple pole MCB 20A 2
8 Triple pole Main switch 60A 1
9 DOL starter 240Vac 2
10 3 phase induction motor 2hp 415 Vac 1
11 1 phase induction motor 1
12 Metal trunking 30 mm x30 mm As required
13 Self tapping Wood screw 4 mm x 20 mm As required
14 DIN rail 25 mm x 1mm
15 GI steel rigid conduit 20mm As required
16 Flexible conduit 20mm As required
17 End box 20 mm 4
18 Flexible wires 05 mm As required
19 Connectors 10 A As required
Procedures
1 Identify each components and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
4 Test the functionality of completed project
1 dead circuit 2 life circuit test
5 Record the current drawn by the load as connected in star and delta
Note Proper earthing should be made
53 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 8 INSPECTION AND TESTING OF ELECTRICAL INSTALLATION
On completion of a wiring installation a number of tests on the installation have to be conducted to
ascertain that the wiring circuits and connected appliances are safe for use Prior to carrying out the
tests an inspection has to be done The results of the inspectionsupervision and test have to be
presented in Form G (as in Appendix IV) and Form H (as in Appendix V)
To have the test certification as in Form H the following tests shall be conducted
i Continuity Test
ii Insulation Resistance Test
iii Polarity Test
iv Earth Electrode Resistance test and
v Residual Current Device Test
1 Continuity Test
There are 3 main types of continuity tests for the final circuits-
i Protection Conductor Continuity Test
ii Final Ring Circuit Conductor Continuity Test
iii Live and Neutral Conductor Continuity Test
a) Protection Conductor Continuity Test
bull To ascertain that all protection conductors are connected in the correct and effective manner
bull Test equipment ndash Multimeter (Ohm range) or Ohm meter
54 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
bull Test Method
1 1048766 Ensure that the main switch RCD and MCB are open circuited (switched off) and all loads
are disconnected
2 1048766 Connected the test leads as in the Figure 81 The meter reading shall be less than 1 Ω
55 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Final Ring Circuit Conductor Continuity Test
bull To ensure that all conductors around the ring circuit have continuity
bull Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
bull Test Method
1 1048766 Disconnect both the supply source live conductors from the MCB the neutral conductor
from the neutral terminals and the earth conductor from the earth terminal in the distribution
fuse box
2 1048766 Connect the test leads as in the Figure 82 (EE)
3 1048766 Repeat the procedure for (L-L) and (N-N)
4 1048766 The meter reading value shall be less than 1 ohm
56 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Live and Neutral Conductor Continuity Test
a To ensure that each conductor in the circuit has continuity
b Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
2 Test Method
1 1048766 Switch off the Main switch RCD and MCB
2 1048766 Disconnect all loads
3 1048766 Switch on all switches in the circuit
4 1048766 Disconnect the fusesfinal circuit breakers and close the circuit
5 1048766 Carry out the test as shown in Figure 83
6 1048766 The meter reading value shall be less than 1Ω
57 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
58 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
CONTINUITY TEST
Insulation Resistance Test
i Ensure that there is no leakage current between phase conductors phase and neutral conductors and
phase conductor and earth
ii Test the strength of the cable insulation
iii Test Equipment ndash Insulation Resistance Tester operating voltage is 250VDC or 500VDC
iv Test Method
1 1048766 Switch off main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
59 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
4 1048766 Carry out test as in the Table below
5 1048766 Meter reading value shall be less than 1 Megaohm
60 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
61 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Insulation resitance test
62 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
INSULATION RESISTANCE TEST BETWEEN CONDUCTORS AND OPPOSITE POLARITY
Polarity Testi Ensure that each fuse or single pole control and protection device is connected only in the phase
conductor
ii Intermediate contact of Edison screw lamp holder is connected to the phase conductor
iii Ensure that phase neutral and earth conductors at socket outlets are connected at the correct
terminals
iv Test Equipment ndash Multimeter (Ohm range) or Ohm meter
v Test Method
1 1048766 Switch off Main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in Figure 85
63 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
5 1048766 Test switches and single phase control devices at the phase conductors
6 1048766 Test socket outlet connection sources
7 1048766 Test Edison screw lamp holder connections
8 1048766 Meter reading value shall be less than 1 Ω
64 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Polarity test
65 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Earth Electrode Resistance Testi To test the earth electrode resistance
ii To ascertain the suitability of the location of the electrode
iii To ensure that the electrode is not buried within the resistance area of another electrode
iv Test equipment ndash Earth Resistance Tester
v Test method -
1 1048766 Terminal rsquoErsquo is connected to the electrode to be tested (green conductor)
2 1048766 Terminal lsquoPrsquo is connected to the potential spike (yellow conductor) at a distance of 10
meters from the earth electrode
3 1048766 Terminal lsquoCrsquo is connected to the current spike (red conductor) at a distance of 20 meters
from the earth electrode
Earth Electrode Resistance Measurement Method (Figure 86)
This test must be repeated at least three times to ensure that the reading is not affected by interacting
earthing regions
i Record the first reading (Z1) Example Z1 = 10 Ω
ii Move the voltage spike to a distance of 6 meters from the original position Record the second
reading (Z2 ) Example Z2 = 10 Ω
iii Move the voltage spike to a distance of 6 meters from the original position Record the third
reading (Z3) Example Z3 = 10 Ω
66 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Residual Current Device Testi Ensure that the residual current device (RCD) trips within the set time on the occurrence of current
leakage to earth
ii Test Equipment ndash RCD Tester RCCB Tester
iii Test Method 1
1 1048766 Use the Trip Test Button
2 1048766 Press the trip button found on the RCD to determine if it trips or otherwise This test would
not be able to determine the sensitivity of the RCD nor the time taken for it to trip
iv Test Method 2
i 1048766 Use a RCD Tester
ii This equipment is equipped with a 13A plug which can be connected to a 13A socket outlet
Select the RCD sensitivity to be the same as the sensitivity of the RCD to be tested to
determine if the RCD can trip The time to trip shall not exceed 40 mS
iii 1048766 Test method ndash
a) Position the selection switch in accordance with the sensitivity of the RCD used
Example 100 mA 01 A
b) Position the operations switch to lsquoNo Triprsquo (frac12 Rated mA = 50) connect the 3 pin plug to
the 13A socket outlet
67 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
c) Switch on the 13A socket outlet ndash ensure that the P-N and P-E lights light up
This shows that the polarity is correct (Note if both the lights as above do not light up the test cannot
be continued)
d) Press the test button ndash the reading shows less than 200 mS and simultaneously the lsquotestrsquo light lights
up and the P-N and P-E lights do not light up At that instant the RCD will not trip
e) Move the selection switch to 180o (+ve wave) ndash repeat steps (d) and (e) Move the operations
switch to lsquoTriprsquo (Rated mA = 100)
g) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200mS
h) Move the selection switch to 0o (-ve wave)
i) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
j) The above test is repeated until a near correct reading is obtained
k) Record the test results
l) Change the operations switch to lsquoFast Triprsquo and press the test button ndash RCD will trip within a
time not exceeding 40 millisecond
m) Repeat a number of times at 0o or 180o
On completion of a wiring installation a number of tests on the installation have to be conducted to
ascertain that the wiring circuits and connected appliances are safe for use Prior to carrying out the
tests an inspection has to be done the following tests shall be conducted
i Continuity Test
ii Insulation Resistance Test
iii Polarity Test
iv Earth Electrode Resistance test and
v Residual Current Device Test
821 Continuity Test
There are 3 main types of continuity tests for the final circuits-
i Protection Conductor Continuity Test
ii Final Ring Circuit Conductor Continuity Test
68 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
iii Live and Neutral Conductor Continuity Test
a) Protection Conductor Continuity Test
bull To ascertain that all protection conductors are connected in the correct and effective manner
bull Test equipment ndash Multimeter (Ohm range) or Ohm meter
bull Test Method
1 1048766 Ensure that the main switch RCD and MCB are open circuited (switched off) and all loads are
disconnected
2 1048766 Connected the test leads as in the Figure 81
3 1048766 The meter reading shall be less than 1 Ω
Final Ring Circuit Conductor Continuity Test
bull To ensure that all conductors around the ring circuit have continuity
bull Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
bull Test Method
1 1048766 Disconnect both the supply source live conductors from the MCB the neutral conductor
from the neutral terminals and the earth conductor from the earth terminal in the distribution
fuse box
2 1048766 Connect the test leads as in the Figure 82 (EE)
3 1048766 Repeat the procedure for (L-L) and (N-N)
4 1048766 The meter reading value shall be less than 1 ohm Figure 82 - Final Ring Circuit Conductor
Continuity Test Ohm Meter
Disconnect both the supply source cables from mcbfuse
Take readings at earth conductors of both sources and note resistance readings
Live and Neutral Conductor Continuity Test
1 To ensure that each conductor in the circuit has continuity
2 Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
3 Test Method
1 1048766 Switch off the Main switch RCD and MCB
2 1048766 Disconnect all loads
3 1048766 Switch on all switches in the circuit
4 1048766 Disconnect the fusesfinal circuit breakers and close the circuit
5 1048766 Carry out the test as shown in Figure 83
6 1048766 The meter reading value shall be less than 1 ohm Figure 83 - Live and Neutral
Conductor Continuity Test Ohm Meter
Insulation Resistance Test
69 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
i Ensure that there is no leakage current between phase conductors phase and neutral conductors and
phase conductor and earth
ii Test the strength of the cable insulation
iii Test Equipment ndash Insulation Resistance Tester Operating voltage is 250VDC or 500VDC
iv Test Method
1 1048766 Switch off main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in the Table below
5 1048766 Meter reading value shall be less than 1 Megaohm
Polarity Test
i Ensure that each fuse or single pole control and protection device is connected only in the phase
conductor
ii Intermediate contact of Edison screw lamp holder is connected to the phase conductor
iii Ensure that phase neutral and earth conductors at socket outlets are connected at the correct
terminals
iv Test Equipment ndash Multimeter (Ohm range) or Ohm meter
v Test Method
1 1048766 Switch off Main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in Figure 85
5 1048766 Test switches and single phase control devices at the phase conductors
6 1048766 Test socket outlet connection sources
7 1048766 Test Edison screw lamp holder connections
8 1048766 Meter reading value shall be less than 1 Ω
Earth Electrode Resistance Test
i To test the earth electrode resistance
70 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
ii To ascertain the suitability of the location of the electrode
iii To ensure that the electrode is not buried within the resistance area of another electrode
iv Test equipment ndash Earth Resistance Tester
v Test method -
1 1048766 Terminal rsquoErsquo is connected to the electrode to be tested (green conductor)
2 1048766 Terminal lsquoPrsquo is connected to the potential spike (yellow conductor) at a distance of 10
meters from the earth electrode
3 1048766 Terminal lsquoCrsquo is connected to the current spike (red conductor) at a distance of 20 meters
from the earth electrode E P C Electrode 10 meter 10 meter
Figure 86 ndash Earth Electrode Resistance Measurement Test Equipment
Earth Electrode Resistance Measurement Method (Figure 86)
This test must be repeated at least three times to ensure that the reading is not affected by interacting
earthing regions
i Record the first reading (Z1) Example Z1 = 10 Ω
ii Move the voltage spike to a distance of 6 meters from the original position Record the second
reading (Z2) Example Z2 = 10 Ω
iii Move the voltage spike to a distance of 6 meters from the original position Record the third
reading (Z3)
Example Z3 = 10 Ω
Residual Current Device Test
71 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
i Ensure that the residual current device (RCD) trips within the set time on the occurrence of current
leakage to earth
ii Test Equipment ndash RCD Tester RCCB Tester
iii Test Method 1
1 1048766 Use the Trip Test Button
2 1048766 Press the trip button found on the RCD to determine if it trips or otherwise This test would
not be able to determine the sensitivity of the RCD nor the time taken for it to trip
iv Test Method 2
1048766 Use a RCD Tester
This equipment is equipped with a 13A plug which can be connected to a 13A socket outlet Select the
RCD sensitivity to be the same as the sensitivity of the RCD to be tested to determine if the RCD can
trip The time to trip shall not exceed 40 mS
1048766 Test method ndash
a) Position the selection switch in accordance with the sensitivity of the RCD used
Example 100 mA 01 A
b) Position the operations switch to lsquoNo Triprsquo (frac12 Rated mA = 50) connect the 3 pin plug to
the 13A socket outlet
c) Switch on the 13A socket outlet ndash ensure that the P-N and P-E lights light up This shows that
the polarity is correct (Note if both the lights as above do not light up the test cannot be
continued)
d) Press the test button ndash the reading shows less than 200 millisecond and simultaneously the
lsquotestrsquo light lights up and the P-N and P-E lights do not light up At that instant the RCD will
not trip
e) Move the selection switch to 180o (+ve wave) ndash repeat steps (d) and (e) = 100)
f) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
g) Move the selection switch to 0o (-ve wave)
h) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
i) The above test is repeated until a near correct reading is obtained
j) Record the test results
k) Change the operations switch to lsquoFast Triprsquo and press the test button ndash RCD will trip within a
time not exceeding 40 mS
l) Repeat a number of times at 0o or 180o
72 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 9 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (DC)
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
73 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Start stop button 240Vac 5A 2
9 Filament lamp (Bulb ) 240Vac 40W 3
10 Overload Relay 415V 20A 3
11 Three phase induction motor 5 hp 3
12 Single phase step down transformer 2500VA 1
13 Single core PVC insulated Cable 1mm 2 As required
14 Single core PVC insulated Cable 25mm 2 As required
15 DIN rail 35 mm As required
16 PVC type Cable tray 50 mm x 50 mm As required
17 Cable ties 4 ldquo As required
18 Flexible wires 05 mm As required
19 PVC Connectors 5 A amp 20 A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the schematic
diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a optional exercise
i Simple DOL starter
ii Forward reverse DOL starter
iii Forward Reverse Dahlander motor
iv Three motors operated in sequence by DOL starter operated by manual push
button or time delay relay
74 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
a One loop per-cycle
b Continuous operation in a loop
c optional circuit design to represent the same task
v Only one out of three motors to be operated at a time (quiz)
4 Test the functionality of completed project
LESSON 10 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (AC)
75 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 1
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Lamp point 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
76 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
11 Overload Relay 415V 20A 3
12 Three phase induction
motor
5 hp 3
13 Single core PVC insulated
Cable
1mm 2 As required
14 Single core PVC insulated
Cable
25mm 2 As required
15 DIN rail 35 mm As required
16 PVC type Cable tray 50 mm x 50 mm As required
17 Cable ties 4 ldquo As required
18 Flexible wires 05 mm As required
19 PVC Connectors 5 A amp 20 A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the
schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram optional exercise
4 Simple DOL starter
5 Forward reverse DOL starter
6 Test the functionality of completed project
77 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 1
78 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
cm
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Indicating light 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
11 Overload Relay 415V 20A 3
12 Three phase induction motor 5 hp 3
13 Single phase step down
transformer
2500VA 1
14 Single core PVC insulated
Cable
1mm 2 As required
15 Single core PVC insulated
Cable
25mm 2 As required
16 DIN rail 35 mm As required
17 PVC type Cable tray 50 mm x 50 mm As required
18 Cable ties 4 ldquo As required
19 Flexible wires 05 mm As required
20 PVC Connectors 5 A amp 20 A 240 V As required
21 Single pole MCB 6A 240 V 1
22 Single pole MCB 2A 240 V 1
23 Triple pole MCB 20A 415 V 1
24 Mounting board 30 cm x 40 cm x 3
cm
1
25 Relay cw 11 pin socket 10 A 240 Vac 2
26 Time delay relay 10 A 240 Vac 3
27 Triple pole Contactor 20A 240Vac 3
28 Batten type Lamp holder 240Vac 10 A 3
29 Start stop button 240Vac 10A 2
30 Indicating light (Bulb ) 240Vac 25W 3
31 Overload Relay 415V 20A 1
32 Three phase dahlander type
induction motor
5 hp 1
33 Single phase step down
transformer
24024Vac
2500VA
1
79 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
34 Single core PVC insulated
Cable
1mm 2 As required
35 Single core PVC insulated
Cable
25mm 2 As required
36 DIN rail 35 mm As required
37 PVC type Cable tray 50 mm x 50 mm As required
38 Cable ties 4 ldquo As required
39 Flexible wires 075 mm As required
40 PVC Connectors 5 A amp 20 A 240 V As required
41 Terminal block 20A 240Vac As required
Procedures
5 Identify each component according to specification and quantity required from the schematic
diagram attached
6 Test the functionality of each component by using multi-meter or power supply whichever
applicable
7 Wire component according to circuit diagram
8 Three motors operated in sequence by DOL starter operated by manual push button or time
delay relay
a One loop per-cycle
b Continuous operation in a loop
c optional circuit design to represent the same task
d Only one out of three motors to be operated at a time (quiz)
9 Test the functionality of completed project
80 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
BASIC DESIGN INDUSTRIAL MOTOR CONTROL (SEQUENCE CONTROL)
THREE PHASE INDUCTION MOTOR OPERATED IN SEQUENCE BY DIRECT ON LINE
STARTER
LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
81 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
82 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Lcd lamp indicator 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
11 Overload Relay 415V 20A 3
12 Three phase induction motor 5 hp 3
13 Single phase step down transformer 2500VA 1
14 Single core PVC insulated Cable 1mm 2 As required
15 Single core PVC insulated Cable 25mm 2 As required
16 DIN rail 35 mm As required
17 PVC type Cable tray 50 mm x 50 mm As required
18 Cable ties 4 ldquo As required
19 Flexible wires 1 mm Oslash As required
20 PVC Terminal block 10A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the schematic
diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a optional exercise
i Forward Reverse dahlander motor
4 Test the functionality of completed project
83 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
THREE PHASE DAHLANDER TYPE INDUCTION MOTOR OPERATED FORWARD AND
REVERSE OPERATION BY DIRECT ON LINE STARTER
84 ndash 99EASYTECH ENTERPRISE
LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
Introduction
If a motors windings are connected in the star configuration any two phases will be in series across
the supply and hence the line current will be smaller(by 577) than if the windings were connected in
the delta arrangement
Hence larger-type motors with heavy starting currents are first connected in star and then when the
starting currents fall in delta This of course means that all six of the ends of the windings must be
brought to terminations outside the casing (Fig 833)
EZTECH
EZTECH ELECTRICAL INSTALLATION GUIDE
The automatic version of this starter incorporates a timing relay which automatically changes the
connections from star to delta Figs 834 and 835 show the wiring and schematic diagrams for a star
delta starter
Objectives
1 Identify component and the specification
2 Design forward reverse star delta starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
2 ndash 99EASYTECH ENTERPRISE
REV -C
LEGENDMCCB Moulded Case Circuit BreakerTOR Thermal Over Load RelayFOW-C Mains Forward ContactorREV-C Mains Reverse ContactorDC Delta ContactorSC Star ContactorS-SW Mains Selector Switch
SC
V2
W2
U2
DC
V1
W1
U1
TOR
TOR
FOW-C
30A MCCB
TOR
MAIN CIRCUIT FORWARD REVERSE STAR DELTA
RYBN S
-SW
3 PHASEINDUCTION MOTOR
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Relay 10 A 240V 3
5 Triple pole Contactor
6 cw NO NC auxiliary contact
240Vac 20 A 4
7 Overload Relay 415 V 1
8 LED indicator 240vac 5 A 4
9 Start stop button 240Vac 5A 2
10 DIN rail 35 mm As required
11 Flexible wires 1 mm As required
12 Single core PVC insulated
wire
25 mm As required
13 Terminal block 20 A As required
14 Squirrel cage motor 5kW 1
15 5 pin plug and socket 415V 20A 1
16 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
3 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
a Manual star delta
b Manual Forward reverse star delta starter
c Automatic star delta starter
d Automatic Forward reverse star delta starter
4 Test the functionality of completed project
4 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
Objectives
1 Identify component and the specification
2 Design auto transformer starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
5 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Autotransformer starter is used to start a 3 phase induction motor that has a rating between 10 to 15 hp
6 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Autotransformer set 10Kw 415 V 50 Hz 1
5 Triple pole Contactor 240Vac 4
6 Batten type Lamp holder 240 Vac 105 A 4
7 Start stop button 240Vac 10A 4
8 Filament lamp (Bulb ) 240Vac 40W 4
9 DIN rail 35 mm As required
10 Flexible wires 1 mm As required
7 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
11 Single core PVC insulated
wire
25 mm As required
12 Terminal block 20 A As required
13 Squirrel cage motor 10kW 1
14 5 pin plug and socket 415V 20A 1
15 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a open transient autotransformer starter
b close transient autotransformer starter
c Forward reverse autotransformer starter
4 Test the functionality of completed project
8 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
Objectives
1 Identify component and the specification
2 Design rotor resistance starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
9 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Rotor Resistor set 10kW 1
5 Triple pole Contactor 240Vac 20A 4
6 Indicating light 240vac 5 A 4
7 Start stop push button 240Vac 5A 4
8 DIN rail 35 mm As required
9 Flexible wires 1 mm 2 As required
10 Single core PVC insulated wire 25 mm 2 As required
11 Terminal block 20 A As required
12 Slip Ring motor 10kW 1
13 5 pin round 3 phase socket 415V 20A 1
14 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
10 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
4 Test the functionality of completed project
a Dead circuit test b Life circuit test
5 Measure starting and running Amps
LESSON 16
TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
An installation in general will suffer damage
Damage usually occurs on the electric motor control as follows
1 Damage to the main circuit
2 Damage to the control circuit
The cause of the damage
i Overcurrent overload short circuit
ii Leakage current to ground
iii Equipment malfunction
iv The main control circuit
a Trip of main circuit protection devices fire
b Defect of motor terminal such as short circuit fire loose
v The control circuit is not functioning -
a contactor relay relay time overload relay does not work damaged burned
b Loose cable connection disconnected
Detecting and Repairing Damage
Examples of damage are as follows
i Motor does not work
ii Motor function and overload relay trips
iii Motor function but only partially functional control circuit
Methods of detecting damage
Among the known methods necessary to detect damage are as follows
1 Turn off the electricity at the main switch (main switch) in order to avoid any danger during the
work carried out to detect damage
2 Check all the protective gear that controls the motor control main circuit
11 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
3 Make sure the damage function control circuit
4 Check the control circuit according to the schematic circuit diagram of the motor control
5 Check the operation of the control circuit
Note
Use wiring that has been installed on the SYSTEM OF MOTOR CONTROL BOARD by Forward
Reverse control circuit for Star Delta to test and look for damage
SELF-ASSESSMENT QUESTIONS
1 (a) Explain what is meant by the term lsquoback emfrsquo in a motor
(b) Outline the basic differences between series shunt and compound wound dc motors
2 (a) With the aid of diagrams explain how the speed of series shunt and compound-wound motors
may be controlled
(b) A 440V dc shunt-wound motor has a field resistance of 200R and an armature resistance of 06 R
When its speed is 20 rev d second the current drawn from the supply is 122A Calculate its back
emf at this speed If the speed were decreased to 19 revssecond the field flux remaining unchanged
calculate the new back emf and the new armature current
3 A load of 64 kW at 240 V is supplied from the terminals of a shunt-wound dc generator The field
resistance is 180 A Calculate the armature current
4 (a) Explain with the aid of a diagram how a rotating magnetic field may be
(b) What is meant by lsquosynchronous speedrsquo
Calculate the synchronous obtained speed of a 12 pole motor if the supply frequency is 50Hz
5 (a) Explain the action of a synchronous motor
(b) What methods are available to start a synchronous motor Explain with diagrams
6 (a) Explain the action of a cage induction motor
(b) What is meant by the term lsquosliprsquo
Calculate the percentage slip of a six pole induction motor running at 162 revssecond from a 50 Hz
supply
7 Describe with sketches three different ways of starting a single-phase induction motor
12 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
8 Explain with the aid of a sketch the action of a three-phase DOL starter
What are dashpots used for How are remote start and stop buttons connected
9 A I0 kW 240V 50Hz single-phase cage rotor induction motor is 85efficient and has a PF of 068
lagging Calculate the motor current and the value of capacitor required to raise the PF to 093
lagging
10 Calculate the torque developed by an 18 kW four-pole induction motor run at 35 slip from a
50Hz supply
APPENDIX 1
13 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 11
14 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 111
Attachment Reference
httpswwwtlc-directcoukBook621htm
httpwwwstgovmyindexphpms
15 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify conduit fitting and the specification
2 Measure and Cut steel conduit according to specified dimension
3 Bend and fabricate conduit at 45 90 according to layout diagram
4 Wire component according to the schematic diagram
5 Test the functionality of the circuit
39 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Conduit Bender Oslash 19 mm ( frac34 ldquo) 1
2 Measuring Tape 3 metre 1
3 Hacksaw frame and blade 30cm 1
4 Conduit cutter 1
5 Pipe Vise 1
6 Pipe Wrench 1
7 Ratchet Dies 20 mm 1
8 Metal trunking 50 mm x 50 mm 1
9 GI conduit 20mm 1
10 End box 20 mm 1
11 Flexible wires 05 mm As required
12 Connectors 5 A As required
13 Single core PVC ins Cable 25 mm 2 As required
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Wire two unit of 13 A socket outlet in radial circuit
3 Wire four unit of 13 A socket outlet in ring circuit
4 Wire one unit DOL starter for air-conditioner point
5 Wire one unit of cooker control unit point
6 Wire one unit of water heater point
7 Test the functionality of each component by using multimeter or power supply whichever
applicable
8 Wire component according to circuit diagram
9 Test the functionality of completed project
Note
Ensure that the rating of protection device and size of wire
K prior to 31 March
2004 (BS 7671)
(formerly)
bare conductor
sleeved at terminations (formerly)
40 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 5 ndashWIRING SYSTEM OF 1 Oslash LIGHTING AND POWER CIRCUIT
POWER CIRCUITSa Radial circuits
Radial circuits are arranged in the same way as item 1 above in lighting layouts in that each socket
outlet is supplied via the previous one
Points to note
1 The number of socket outlets complying with BS 1363 is unlimited for a floor area of up to 50m 2 if
the circuit protection is a 30 A or 32 A cartridge fuse or circuit breaker the cable being 4 mm PVC
copper or 25 mm2 mineral insulated (mi)
2 The number of socket outlets is unlimited for a floor area up to 20 m 2 with any type of circuit
protection of 20 A using 25 mm2 PVC copper cable or 15 mm2 mi
3 The total number of fused spurs is unlimited
b ring final circuits
These circuits are the same as radial circuits except that the final socket outlet is wired back to the
supply position In effect any outlet is supplied from two directions (Fig 152)
Points to note
1 Every twin-socket outlet counts as two single-socket outlets
2 The number of non-fused spurs must not exceed the total number of points on the ring Fig 158
shows seven points on the ring and five spurs
3 The fuse rating of a fused spur box must not exceed 13 A and the current rating of all points supplied
by the fused spur must not exceed 13 A
4 Non-fused spurs must supply no more than one single or one double socket on the ring Fig 158
shows seven points on the ring and five spurs rating of all points supplied by the fused spur must not
exceed 13 A or one stationary appliance
CapacityMain conductor size
copper (mm2)
Earth conductor
size (mm2)
Circuit breaker
capacity (A)
Up to 600 W 15 15 6
600ndash1200 W 1525 15 10
1200ndash1800 W 254 25 16
41 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Ring circuit
(floor area 100 m2)25 15 3032
A2 radial circuit
(floor area 75 m2)40 25 3032
A3 radial circuit
(floor area 50 m2)25 15 20
Air conditioner (15 tonne) 60 60 3032
Cooker 60 60 3032
Water heater 40 40 20
Objectives
1 Identify component and the specification
2 Wire component according to the schematic diagram
3 Test the functionality of the circuit
42 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board Perforated 1
2 Cut out fuse and neutral link 60A 240V 1each
3 kWh meter 240V 40A 1
4 Switched Socket outlet 13A 240Vac 4
5 Single pole two way switch cw switch
box
5A 240Vac 2
6 RCCB ELCB 63 A Tripping current 100mA
415 Vac
1
7 3 pin plug 240Vac 13A 4
8 Single pole MCB 20 A 2
9 Single pole MCB 6A 1
10 Single pole MCB 20A 2
11 DOL starter 240Vac 2
12 1 phase induction motor 2hp 240 Vac 1
13 Self tapping Wood screw As required
14 DIN rail Stainless steel allum35 mm As required
15 PVC pipe 20mm dia As required
16 End box 20 mm dia 4
17 Flexible wires 05 mm 2 As required
18 Connectors 5 A As required
Procedures
43 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
4 Test the functionality of completed project
LESSON 6 ndash WIRING SYSTEM OF 3 Oslash DISTRIBUTION BOARD
Introduction
44 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
45 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
46 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
47 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
48 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify each component and the specification
2 Wire component according to the schematic diagram given
3 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting Board 450 x 600 mm Perforated metal 1
2 5 pin round socket and plug 415V ac 32A 1
3 Cut out fuse 60 A 3
4 Neutral link 1
5 kWatt hour meter 415V 60A 1
6 ELCB RCCB 3P+N In=63A415 Vac I trip= 300mA 1
7 ELCB RCCB 3P+N In=63A415 Vac I trip= 30mA 1
8 Single pole MCB 6A 240 V 3
9 Single pole MCB 20A 240 V 3
10 DOL starter 20 A 240Vac 2
11 Socket outlet 15 A 240 Vac 1
12 Switched Socket outlet 13 A 240 Vac 3
13 Led indicating light 5A 240 Vac 3
14 Single pole 4 gang 1 way switch 5A 240 Vac 2
15 Single pole 2 way switch 5A 240 Vac 2
16 1 phase induction motor 1 kW 240Vac 1
17 Metal trunking 30 mm x30 mm As required
18 Self tapping Wood screw 4 mm x 20 mm As required
19 DIN rail 25 mm x 1mm
20 GI steel rigid conduit 20mm As required
21 Flexible conduit 20mm As required
22 End box 20 mm 4
23 Flexible wires 05 mm 2 As required
24 Single core PVC insulated wire 15 mm 2 As required
25 Single core PVC insulated wires 25 mm 2 As required
26 Terminal block 10 A As required
Procedures
49 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify each components and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
4 Test the functionality of completed project
1 dead circuit test
2 life circuit
Note Proper earthing should be made
50 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 7 ndash WIRING SYSTEM OF THREE PHASE LIGHTING AND POWER CIRCUIT
51 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
52 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify component and the specification
2 Wire component according to the schematic diagram
3 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting bay Board Perforated metal 180 cm x 180 cm 1
2 k Watt hour meter 415V 60A 1
3 MCCB 415V 60A
4 ELCB RCCB In=60A415 Vac I trip=30mA 1
5 5 pin round Socket and
plug
415Vac 32A 4
6 Single pole MCB 6A 1
7 Triple pole MCB 20A 2
8 Triple pole Main switch 60A 1
9 DOL starter 240Vac 2
10 3 phase induction motor 2hp 415 Vac 1
11 1 phase induction motor 1
12 Metal trunking 30 mm x30 mm As required
13 Self tapping Wood screw 4 mm x 20 mm As required
14 DIN rail 25 mm x 1mm
15 GI steel rigid conduit 20mm As required
16 Flexible conduit 20mm As required
17 End box 20 mm 4
18 Flexible wires 05 mm As required
19 Connectors 10 A As required
Procedures
1 Identify each components and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
4 Test the functionality of completed project
1 dead circuit 2 life circuit test
5 Record the current drawn by the load as connected in star and delta
Note Proper earthing should be made
53 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 8 INSPECTION AND TESTING OF ELECTRICAL INSTALLATION
On completion of a wiring installation a number of tests on the installation have to be conducted to
ascertain that the wiring circuits and connected appliances are safe for use Prior to carrying out the
tests an inspection has to be done The results of the inspectionsupervision and test have to be
presented in Form G (as in Appendix IV) and Form H (as in Appendix V)
To have the test certification as in Form H the following tests shall be conducted
i Continuity Test
ii Insulation Resistance Test
iii Polarity Test
iv Earth Electrode Resistance test and
v Residual Current Device Test
1 Continuity Test
There are 3 main types of continuity tests for the final circuits-
i Protection Conductor Continuity Test
ii Final Ring Circuit Conductor Continuity Test
iii Live and Neutral Conductor Continuity Test
a) Protection Conductor Continuity Test
bull To ascertain that all protection conductors are connected in the correct and effective manner
bull Test equipment ndash Multimeter (Ohm range) or Ohm meter
54 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
bull Test Method
1 1048766 Ensure that the main switch RCD and MCB are open circuited (switched off) and all loads
are disconnected
2 1048766 Connected the test leads as in the Figure 81 The meter reading shall be less than 1 Ω
55 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Final Ring Circuit Conductor Continuity Test
bull To ensure that all conductors around the ring circuit have continuity
bull Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
bull Test Method
1 1048766 Disconnect both the supply source live conductors from the MCB the neutral conductor
from the neutral terminals and the earth conductor from the earth terminal in the distribution
fuse box
2 1048766 Connect the test leads as in the Figure 82 (EE)
3 1048766 Repeat the procedure for (L-L) and (N-N)
4 1048766 The meter reading value shall be less than 1 ohm
56 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Live and Neutral Conductor Continuity Test
a To ensure that each conductor in the circuit has continuity
b Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
2 Test Method
1 1048766 Switch off the Main switch RCD and MCB
2 1048766 Disconnect all loads
3 1048766 Switch on all switches in the circuit
4 1048766 Disconnect the fusesfinal circuit breakers and close the circuit
5 1048766 Carry out the test as shown in Figure 83
6 1048766 The meter reading value shall be less than 1Ω
57 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
58 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
CONTINUITY TEST
Insulation Resistance Test
i Ensure that there is no leakage current between phase conductors phase and neutral conductors and
phase conductor and earth
ii Test the strength of the cable insulation
iii Test Equipment ndash Insulation Resistance Tester operating voltage is 250VDC or 500VDC
iv Test Method
1 1048766 Switch off main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
59 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
4 1048766 Carry out test as in the Table below
5 1048766 Meter reading value shall be less than 1 Megaohm
60 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
61 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Insulation resitance test
62 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
INSULATION RESISTANCE TEST BETWEEN CONDUCTORS AND OPPOSITE POLARITY
Polarity Testi Ensure that each fuse or single pole control and protection device is connected only in the phase
conductor
ii Intermediate contact of Edison screw lamp holder is connected to the phase conductor
iii Ensure that phase neutral and earth conductors at socket outlets are connected at the correct
terminals
iv Test Equipment ndash Multimeter (Ohm range) or Ohm meter
v Test Method
1 1048766 Switch off Main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in Figure 85
63 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
5 1048766 Test switches and single phase control devices at the phase conductors
6 1048766 Test socket outlet connection sources
7 1048766 Test Edison screw lamp holder connections
8 1048766 Meter reading value shall be less than 1 Ω
64 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Polarity test
65 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Earth Electrode Resistance Testi To test the earth electrode resistance
ii To ascertain the suitability of the location of the electrode
iii To ensure that the electrode is not buried within the resistance area of another electrode
iv Test equipment ndash Earth Resistance Tester
v Test method -
1 1048766 Terminal rsquoErsquo is connected to the electrode to be tested (green conductor)
2 1048766 Terminal lsquoPrsquo is connected to the potential spike (yellow conductor) at a distance of 10
meters from the earth electrode
3 1048766 Terminal lsquoCrsquo is connected to the current spike (red conductor) at a distance of 20 meters
from the earth electrode
Earth Electrode Resistance Measurement Method (Figure 86)
This test must be repeated at least three times to ensure that the reading is not affected by interacting
earthing regions
i Record the first reading (Z1) Example Z1 = 10 Ω
ii Move the voltage spike to a distance of 6 meters from the original position Record the second
reading (Z2 ) Example Z2 = 10 Ω
iii Move the voltage spike to a distance of 6 meters from the original position Record the third
reading (Z3) Example Z3 = 10 Ω
66 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Residual Current Device Testi Ensure that the residual current device (RCD) trips within the set time on the occurrence of current
leakage to earth
ii Test Equipment ndash RCD Tester RCCB Tester
iii Test Method 1
1 1048766 Use the Trip Test Button
2 1048766 Press the trip button found on the RCD to determine if it trips or otherwise This test would
not be able to determine the sensitivity of the RCD nor the time taken for it to trip
iv Test Method 2
i 1048766 Use a RCD Tester
ii This equipment is equipped with a 13A plug which can be connected to a 13A socket outlet
Select the RCD sensitivity to be the same as the sensitivity of the RCD to be tested to
determine if the RCD can trip The time to trip shall not exceed 40 mS
iii 1048766 Test method ndash
a) Position the selection switch in accordance with the sensitivity of the RCD used
Example 100 mA 01 A
b) Position the operations switch to lsquoNo Triprsquo (frac12 Rated mA = 50) connect the 3 pin plug to
the 13A socket outlet
67 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
c) Switch on the 13A socket outlet ndash ensure that the P-N and P-E lights light up
This shows that the polarity is correct (Note if both the lights as above do not light up the test cannot
be continued)
d) Press the test button ndash the reading shows less than 200 mS and simultaneously the lsquotestrsquo light lights
up and the P-N and P-E lights do not light up At that instant the RCD will not trip
e) Move the selection switch to 180o (+ve wave) ndash repeat steps (d) and (e) Move the operations
switch to lsquoTriprsquo (Rated mA = 100)
g) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200mS
h) Move the selection switch to 0o (-ve wave)
i) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
j) The above test is repeated until a near correct reading is obtained
k) Record the test results
l) Change the operations switch to lsquoFast Triprsquo and press the test button ndash RCD will trip within a
time not exceeding 40 millisecond
m) Repeat a number of times at 0o or 180o
On completion of a wiring installation a number of tests on the installation have to be conducted to
ascertain that the wiring circuits and connected appliances are safe for use Prior to carrying out the
tests an inspection has to be done the following tests shall be conducted
i Continuity Test
ii Insulation Resistance Test
iii Polarity Test
iv Earth Electrode Resistance test and
v Residual Current Device Test
821 Continuity Test
There are 3 main types of continuity tests for the final circuits-
i Protection Conductor Continuity Test
ii Final Ring Circuit Conductor Continuity Test
68 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
iii Live and Neutral Conductor Continuity Test
a) Protection Conductor Continuity Test
bull To ascertain that all protection conductors are connected in the correct and effective manner
bull Test equipment ndash Multimeter (Ohm range) or Ohm meter
bull Test Method
1 1048766 Ensure that the main switch RCD and MCB are open circuited (switched off) and all loads are
disconnected
2 1048766 Connected the test leads as in the Figure 81
3 1048766 The meter reading shall be less than 1 Ω
Final Ring Circuit Conductor Continuity Test
bull To ensure that all conductors around the ring circuit have continuity
bull Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
bull Test Method
1 1048766 Disconnect both the supply source live conductors from the MCB the neutral conductor
from the neutral terminals and the earth conductor from the earth terminal in the distribution
fuse box
2 1048766 Connect the test leads as in the Figure 82 (EE)
3 1048766 Repeat the procedure for (L-L) and (N-N)
4 1048766 The meter reading value shall be less than 1 ohm Figure 82 - Final Ring Circuit Conductor
Continuity Test Ohm Meter
Disconnect both the supply source cables from mcbfuse
Take readings at earth conductors of both sources and note resistance readings
Live and Neutral Conductor Continuity Test
1 To ensure that each conductor in the circuit has continuity
2 Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
3 Test Method
1 1048766 Switch off the Main switch RCD and MCB
2 1048766 Disconnect all loads
3 1048766 Switch on all switches in the circuit
4 1048766 Disconnect the fusesfinal circuit breakers and close the circuit
5 1048766 Carry out the test as shown in Figure 83
6 1048766 The meter reading value shall be less than 1 ohm Figure 83 - Live and Neutral
Conductor Continuity Test Ohm Meter
Insulation Resistance Test
69 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
i Ensure that there is no leakage current between phase conductors phase and neutral conductors and
phase conductor and earth
ii Test the strength of the cable insulation
iii Test Equipment ndash Insulation Resistance Tester Operating voltage is 250VDC or 500VDC
iv Test Method
1 1048766 Switch off main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in the Table below
5 1048766 Meter reading value shall be less than 1 Megaohm
Polarity Test
i Ensure that each fuse or single pole control and protection device is connected only in the phase
conductor
ii Intermediate contact of Edison screw lamp holder is connected to the phase conductor
iii Ensure that phase neutral and earth conductors at socket outlets are connected at the correct
terminals
iv Test Equipment ndash Multimeter (Ohm range) or Ohm meter
v Test Method
1 1048766 Switch off Main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in Figure 85
5 1048766 Test switches and single phase control devices at the phase conductors
6 1048766 Test socket outlet connection sources
7 1048766 Test Edison screw lamp holder connections
8 1048766 Meter reading value shall be less than 1 Ω
Earth Electrode Resistance Test
i To test the earth electrode resistance
70 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
ii To ascertain the suitability of the location of the electrode
iii To ensure that the electrode is not buried within the resistance area of another electrode
iv Test equipment ndash Earth Resistance Tester
v Test method -
1 1048766 Terminal rsquoErsquo is connected to the electrode to be tested (green conductor)
2 1048766 Terminal lsquoPrsquo is connected to the potential spike (yellow conductor) at a distance of 10
meters from the earth electrode
3 1048766 Terminal lsquoCrsquo is connected to the current spike (red conductor) at a distance of 20 meters
from the earth electrode E P C Electrode 10 meter 10 meter
Figure 86 ndash Earth Electrode Resistance Measurement Test Equipment
Earth Electrode Resistance Measurement Method (Figure 86)
This test must be repeated at least three times to ensure that the reading is not affected by interacting
earthing regions
i Record the first reading (Z1) Example Z1 = 10 Ω
ii Move the voltage spike to a distance of 6 meters from the original position Record the second
reading (Z2) Example Z2 = 10 Ω
iii Move the voltage spike to a distance of 6 meters from the original position Record the third
reading (Z3)
Example Z3 = 10 Ω
Residual Current Device Test
71 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
i Ensure that the residual current device (RCD) trips within the set time on the occurrence of current
leakage to earth
ii Test Equipment ndash RCD Tester RCCB Tester
iii Test Method 1
1 1048766 Use the Trip Test Button
2 1048766 Press the trip button found on the RCD to determine if it trips or otherwise This test would
not be able to determine the sensitivity of the RCD nor the time taken for it to trip
iv Test Method 2
1048766 Use a RCD Tester
This equipment is equipped with a 13A plug which can be connected to a 13A socket outlet Select the
RCD sensitivity to be the same as the sensitivity of the RCD to be tested to determine if the RCD can
trip The time to trip shall not exceed 40 mS
1048766 Test method ndash
a) Position the selection switch in accordance with the sensitivity of the RCD used
Example 100 mA 01 A
b) Position the operations switch to lsquoNo Triprsquo (frac12 Rated mA = 50) connect the 3 pin plug to
the 13A socket outlet
c) Switch on the 13A socket outlet ndash ensure that the P-N and P-E lights light up This shows that
the polarity is correct (Note if both the lights as above do not light up the test cannot be
continued)
d) Press the test button ndash the reading shows less than 200 millisecond and simultaneously the
lsquotestrsquo light lights up and the P-N and P-E lights do not light up At that instant the RCD will
not trip
e) Move the selection switch to 180o (+ve wave) ndash repeat steps (d) and (e) = 100)
f) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
g) Move the selection switch to 0o (-ve wave)
h) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
i) The above test is repeated until a near correct reading is obtained
j) Record the test results
k) Change the operations switch to lsquoFast Triprsquo and press the test button ndash RCD will trip within a
time not exceeding 40 mS
l) Repeat a number of times at 0o or 180o
72 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 9 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (DC)
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
73 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Start stop button 240Vac 5A 2
9 Filament lamp (Bulb ) 240Vac 40W 3
10 Overload Relay 415V 20A 3
11 Three phase induction motor 5 hp 3
12 Single phase step down transformer 2500VA 1
13 Single core PVC insulated Cable 1mm 2 As required
14 Single core PVC insulated Cable 25mm 2 As required
15 DIN rail 35 mm As required
16 PVC type Cable tray 50 mm x 50 mm As required
17 Cable ties 4 ldquo As required
18 Flexible wires 05 mm As required
19 PVC Connectors 5 A amp 20 A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the schematic
diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a optional exercise
i Simple DOL starter
ii Forward reverse DOL starter
iii Forward Reverse Dahlander motor
iv Three motors operated in sequence by DOL starter operated by manual push
button or time delay relay
74 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
a One loop per-cycle
b Continuous operation in a loop
c optional circuit design to represent the same task
v Only one out of three motors to be operated at a time (quiz)
4 Test the functionality of completed project
LESSON 10 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (AC)
75 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 1
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Lamp point 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
76 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
11 Overload Relay 415V 20A 3
12 Three phase induction
motor
5 hp 3
13 Single core PVC insulated
Cable
1mm 2 As required
14 Single core PVC insulated
Cable
25mm 2 As required
15 DIN rail 35 mm As required
16 PVC type Cable tray 50 mm x 50 mm As required
17 Cable ties 4 ldquo As required
18 Flexible wires 05 mm As required
19 PVC Connectors 5 A amp 20 A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the
schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram optional exercise
4 Simple DOL starter
5 Forward reverse DOL starter
6 Test the functionality of completed project
77 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 1
78 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
cm
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Indicating light 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
11 Overload Relay 415V 20A 3
12 Three phase induction motor 5 hp 3
13 Single phase step down
transformer
2500VA 1
14 Single core PVC insulated
Cable
1mm 2 As required
15 Single core PVC insulated
Cable
25mm 2 As required
16 DIN rail 35 mm As required
17 PVC type Cable tray 50 mm x 50 mm As required
18 Cable ties 4 ldquo As required
19 Flexible wires 05 mm As required
20 PVC Connectors 5 A amp 20 A 240 V As required
21 Single pole MCB 6A 240 V 1
22 Single pole MCB 2A 240 V 1
23 Triple pole MCB 20A 415 V 1
24 Mounting board 30 cm x 40 cm x 3
cm
1
25 Relay cw 11 pin socket 10 A 240 Vac 2
26 Time delay relay 10 A 240 Vac 3
27 Triple pole Contactor 20A 240Vac 3
28 Batten type Lamp holder 240Vac 10 A 3
29 Start stop button 240Vac 10A 2
30 Indicating light (Bulb ) 240Vac 25W 3
31 Overload Relay 415V 20A 1
32 Three phase dahlander type
induction motor
5 hp 1
33 Single phase step down
transformer
24024Vac
2500VA
1
79 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
34 Single core PVC insulated
Cable
1mm 2 As required
35 Single core PVC insulated
Cable
25mm 2 As required
36 DIN rail 35 mm As required
37 PVC type Cable tray 50 mm x 50 mm As required
38 Cable ties 4 ldquo As required
39 Flexible wires 075 mm As required
40 PVC Connectors 5 A amp 20 A 240 V As required
41 Terminal block 20A 240Vac As required
Procedures
5 Identify each component according to specification and quantity required from the schematic
diagram attached
6 Test the functionality of each component by using multi-meter or power supply whichever
applicable
7 Wire component according to circuit diagram
8 Three motors operated in sequence by DOL starter operated by manual push button or time
delay relay
a One loop per-cycle
b Continuous operation in a loop
c optional circuit design to represent the same task
d Only one out of three motors to be operated at a time (quiz)
9 Test the functionality of completed project
80 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
BASIC DESIGN INDUSTRIAL MOTOR CONTROL (SEQUENCE CONTROL)
THREE PHASE INDUCTION MOTOR OPERATED IN SEQUENCE BY DIRECT ON LINE
STARTER
LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
81 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
82 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Lcd lamp indicator 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
11 Overload Relay 415V 20A 3
12 Three phase induction motor 5 hp 3
13 Single phase step down transformer 2500VA 1
14 Single core PVC insulated Cable 1mm 2 As required
15 Single core PVC insulated Cable 25mm 2 As required
16 DIN rail 35 mm As required
17 PVC type Cable tray 50 mm x 50 mm As required
18 Cable ties 4 ldquo As required
19 Flexible wires 1 mm Oslash As required
20 PVC Terminal block 10A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the schematic
diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a optional exercise
i Forward Reverse dahlander motor
4 Test the functionality of completed project
83 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
THREE PHASE DAHLANDER TYPE INDUCTION MOTOR OPERATED FORWARD AND
REVERSE OPERATION BY DIRECT ON LINE STARTER
84 ndash 99EASYTECH ENTERPRISE
LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
Introduction
If a motors windings are connected in the star configuration any two phases will be in series across
the supply and hence the line current will be smaller(by 577) than if the windings were connected in
the delta arrangement
Hence larger-type motors with heavy starting currents are first connected in star and then when the
starting currents fall in delta This of course means that all six of the ends of the windings must be
brought to terminations outside the casing (Fig 833)
EZTECH
EZTECH ELECTRICAL INSTALLATION GUIDE
The automatic version of this starter incorporates a timing relay which automatically changes the
connections from star to delta Figs 834 and 835 show the wiring and schematic diagrams for a star
delta starter
Objectives
1 Identify component and the specification
2 Design forward reverse star delta starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
2 ndash 99EASYTECH ENTERPRISE
REV -C
LEGENDMCCB Moulded Case Circuit BreakerTOR Thermal Over Load RelayFOW-C Mains Forward ContactorREV-C Mains Reverse ContactorDC Delta ContactorSC Star ContactorS-SW Mains Selector Switch
SC
V2
W2
U2
DC
V1
W1
U1
TOR
TOR
FOW-C
30A MCCB
TOR
MAIN CIRCUIT FORWARD REVERSE STAR DELTA
RYBN S
-SW
3 PHASEINDUCTION MOTOR
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Relay 10 A 240V 3
5 Triple pole Contactor
6 cw NO NC auxiliary contact
240Vac 20 A 4
7 Overload Relay 415 V 1
8 LED indicator 240vac 5 A 4
9 Start stop button 240Vac 5A 2
10 DIN rail 35 mm As required
11 Flexible wires 1 mm As required
12 Single core PVC insulated
wire
25 mm As required
13 Terminal block 20 A As required
14 Squirrel cage motor 5kW 1
15 5 pin plug and socket 415V 20A 1
16 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
3 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
a Manual star delta
b Manual Forward reverse star delta starter
c Automatic star delta starter
d Automatic Forward reverse star delta starter
4 Test the functionality of completed project
4 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
Objectives
1 Identify component and the specification
2 Design auto transformer starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
5 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Autotransformer starter is used to start a 3 phase induction motor that has a rating between 10 to 15 hp
6 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Autotransformer set 10Kw 415 V 50 Hz 1
5 Triple pole Contactor 240Vac 4
6 Batten type Lamp holder 240 Vac 105 A 4
7 Start stop button 240Vac 10A 4
8 Filament lamp (Bulb ) 240Vac 40W 4
9 DIN rail 35 mm As required
10 Flexible wires 1 mm As required
7 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
11 Single core PVC insulated
wire
25 mm As required
12 Terminal block 20 A As required
13 Squirrel cage motor 10kW 1
14 5 pin plug and socket 415V 20A 1
15 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a open transient autotransformer starter
b close transient autotransformer starter
c Forward reverse autotransformer starter
4 Test the functionality of completed project
8 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
Objectives
1 Identify component and the specification
2 Design rotor resistance starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
9 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Rotor Resistor set 10kW 1
5 Triple pole Contactor 240Vac 20A 4
6 Indicating light 240vac 5 A 4
7 Start stop push button 240Vac 5A 4
8 DIN rail 35 mm As required
9 Flexible wires 1 mm 2 As required
10 Single core PVC insulated wire 25 mm 2 As required
11 Terminal block 20 A As required
12 Slip Ring motor 10kW 1
13 5 pin round 3 phase socket 415V 20A 1
14 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
10 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
4 Test the functionality of completed project
a Dead circuit test b Life circuit test
5 Measure starting and running Amps
LESSON 16
TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
An installation in general will suffer damage
Damage usually occurs on the electric motor control as follows
1 Damage to the main circuit
2 Damage to the control circuit
The cause of the damage
i Overcurrent overload short circuit
ii Leakage current to ground
iii Equipment malfunction
iv The main control circuit
a Trip of main circuit protection devices fire
b Defect of motor terminal such as short circuit fire loose
v The control circuit is not functioning -
a contactor relay relay time overload relay does not work damaged burned
b Loose cable connection disconnected
Detecting and Repairing Damage
Examples of damage are as follows
i Motor does not work
ii Motor function and overload relay trips
iii Motor function but only partially functional control circuit
Methods of detecting damage
Among the known methods necessary to detect damage are as follows
1 Turn off the electricity at the main switch (main switch) in order to avoid any danger during the
work carried out to detect damage
2 Check all the protective gear that controls the motor control main circuit
11 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
3 Make sure the damage function control circuit
4 Check the control circuit according to the schematic circuit diagram of the motor control
5 Check the operation of the control circuit
Note
Use wiring that has been installed on the SYSTEM OF MOTOR CONTROL BOARD by Forward
Reverse control circuit for Star Delta to test and look for damage
SELF-ASSESSMENT QUESTIONS
1 (a) Explain what is meant by the term lsquoback emfrsquo in a motor
(b) Outline the basic differences between series shunt and compound wound dc motors
2 (a) With the aid of diagrams explain how the speed of series shunt and compound-wound motors
may be controlled
(b) A 440V dc shunt-wound motor has a field resistance of 200R and an armature resistance of 06 R
When its speed is 20 rev d second the current drawn from the supply is 122A Calculate its back
emf at this speed If the speed were decreased to 19 revssecond the field flux remaining unchanged
calculate the new back emf and the new armature current
3 A load of 64 kW at 240 V is supplied from the terminals of a shunt-wound dc generator The field
resistance is 180 A Calculate the armature current
4 (a) Explain with the aid of a diagram how a rotating magnetic field may be
(b) What is meant by lsquosynchronous speedrsquo
Calculate the synchronous obtained speed of a 12 pole motor if the supply frequency is 50Hz
5 (a) Explain the action of a synchronous motor
(b) What methods are available to start a synchronous motor Explain with diagrams
6 (a) Explain the action of a cage induction motor
(b) What is meant by the term lsquosliprsquo
Calculate the percentage slip of a six pole induction motor running at 162 revssecond from a 50 Hz
supply
7 Describe with sketches three different ways of starting a single-phase induction motor
12 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
8 Explain with the aid of a sketch the action of a three-phase DOL starter
What are dashpots used for How are remote start and stop buttons connected
9 A I0 kW 240V 50Hz single-phase cage rotor induction motor is 85efficient and has a PF of 068
lagging Calculate the motor current and the value of capacitor required to raise the PF to 093
lagging
10 Calculate the torque developed by an 18 kW four-pole induction motor run at 35 slip from a
50Hz supply
APPENDIX 1
13 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 11
14 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 111
Attachment Reference
httpswwwtlc-directcoukBook621htm
httpwwwstgovmyindexphpms
15 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Conduit Bender Oslash 19 mm ( frac34 ldquo) 1
2 Measuring Tape 3 metre 1
3 Hacksaw frame and blade 30cm 1
4 Conduit cutter 1
5 Pipe Vise 1
6 Pipe Wrench 1
7 Ratchet Dies 20 mm 1
8 Metal trunking 50 mm x 50 mm 1
9 GI conduit 20mm 1
10 End box 20 mm 1
11 Flexible wires 05 mm As required
12 Connectors 5 A As required
13 Single core PVC ins Cable 25 mm 2 As required
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Wire two unit of 13 A socket outlet in radial circuit
3 Wire four unit of 13 A socket outlet in ring circuit
4 Wire one unit DOL starter for air-conditioner point
5 Wire one unit of cooker control unit point
6 Wire one unit of water heater point
7 Test the functionality of each component by using multimeter or power supply whichever
applicable
8 Wire component according to circuit diagram
9 Test the functionality of completed project
Note
Ensure that the rating of protection device and size of wire
K prior to 31 March
2004 (BS 7671)
(formerly)
bare conductor
sleeved at terminations (formerly)
40 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 5 ndashWIRING SYSTEM OF 1 Oslash LIGHTING AND POWER CIRCUIT
POWER CIRCUITSa Radial circuits
Radial circuits are arranged in the same way as item 1 above in lighting layouts in that each socket
outlet is supplied via the previous one
Points to note
1 The number of socket outlets complying with BS 1363 is unlimited for a floor area of up to 50m 2 if
the circuit protection is a 30 A or 32 A cartridge fuse or circuit breaker the cable being 4 mm PVC
copper or 25 mm2 mineral insulated (mi)
2 The number of socket outlets is unlimited for a floor area up to 20 m 2 with any type of circuit
protection of 20 A using 25 mm2 PVC copper cable or 15 mm2 mi
3 The total number of fused spurs is unlimited
b ring final circuits
These circuits are the same as radial circuits except that the final socket outlet is wired back to the
supply position In effect any outlet is supplied from two directions (Fig 152)
Points to note
1 Every twin-socket outlet counts as two single-socket outlets
2 The number of non-fused spurs must not exceed the total number of points on the ring Fig 158
shows seven points on the ring and five spurs
3 The fuse rating of a fused spur box must not exceed 13 A and the current rating of all points supplied
by the fused spur must not exceed 13 A
4 Non-fused spurs must supply no more than one single or one double socket on the ring Fig 158
shows seven points on the ring and five spurs rating of all points supplied by the fused spur must not
exceed 13 A or one stationary appliance
CapacityMain conductor size
copper (mm2)
Earth conductor
size (mm2)
Circuit breaker
capacity (A)
Up to 600 W 15 15 6
600ndash1200 W 1525 15 10
1200ndash1800 W 254 25 16
41 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Ring circuit
(floor area 100 m2)25 15 3032
A2 radial circuit
(floor area 75 m2)40 25 3032
A3 radial circuit
(floor area 50 m2)25 15 20
Air conditioner (15 tonne) 60 60 3032
Cooker 60 60 3032
Water heater 40 40 20
Objectives
1 Identify component and the specification
2 Wire component according to the schematic diagram
3 Test the functionality of the circuit
42 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board Perforated 1
2 Cut out fuse and neutral link 60A 240V 1each
3 kWh meter 240V 40A 1
4 Switched Socket outlet 13A 240Vac 4
5 Single pole two way switch cw switch
box
5A 240Vac 2
6 RCCB ELCB 63 A Tripping current 100mA
415 Vac
1
7 3 pin plug 240Vac 13A 4
8 Single pole MCB 20 A 2
9 Single pole MCB 6A 1
10 Single pole MCB 20A 2
11 DOL starter 240Vac 2
12 1 phase induction motor 2hp 240 Vac 1
13 Self tapping Wood screw As required
14 DIN rail Stainless steel allum35 mm As required
15 PVC pipe 20mm dia As required
16 End box 20 mm dia 4
17 Flexible wires 05 mm 2 As required
18 Connectors 5 A As required
Procedures
43 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
4 Test the functionality of completed project
LESSON 6 ndash WIRING SYSTEM OF 3 Oslash DISTRIBUTION BOARD
Introduction
44 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
45 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
46 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
47 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
48 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify each component and the specification
2 Wire component according to the schematic diagram given
3 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting Board 450 x 600 mm Perforated metal 1
2 5 pin round socket and plug 415V ac 32A 1
3 Cut out fuse 60 A 3
4 Neutral link 1
5 kWatt hour meter 415V 60A 1
6 ELCB RCCB 3P+N In=63A415 Vac I trip= 300mA 1
7 ELCB RCCB 3P+N In=63A415 Vac I trip= 30mA 1
8 Single pole MCB 6A 240 V 3
9 Single pole MCB 20A 240 V 3
10 DOL starter 20 A 240Vac 2
11 Socket outlet 15 A 240 Vac 1
12 Switched Socket outlet 13 A 240 Vac 3
13 Led indicating light 5A 240 Vac 3
14 Single pole 4 gang 1 way switch 5A 240 Vac 2
15 Single pole 2 way switch 5A 240 Vac 2
16 1 phase induction motor 1 kW 240Vac 1
17 Metal trunking 30 mm x30 mm As required
18 Self tapping Wood screw 4 mm x 20 mm As required
19 DIN rail 25 mm x 1mm
20 GI steel rigid conduit 20mm As required
21 Flexible conduit 20mm As required
22 End box 20 mm 4
23 Flexible wires 05 mm 2 As required
24 Single core PVC insulated wire 15 mm 2 As required
25 Single core PVC insulated wires 25 mm 2 As required
26 Terminal block 10 A As required
Procedures
49 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify each components and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
4 Test the functionality of completed project
1 dead circuit test
2 life circuit
Note Proper earthing should be made
50 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 7 ndash WIRING SYSTEM OF THREE PHASE LIGHTING AND POWER CIRCUIT
51 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
52 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify component and the specification
2 Wire component according to the schematic diagram
3 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting bay Board Perforated metal 180 cm x 180 cm 1
2 k Watt hour meter 415V 60A 1
3 MCCB 415V 60A
4 ELCB RCCB In=60A415 Vac I trip=30mA 1
5 5 pin round Socket and
plug
415Vac 32A 4
6 Single pole MCB 6A 1
7 Triple pole MCB 20A 2
8 Triple pole Main switch 60A 1
9 DOL starter 240Vac 2
10 3 phase induction motor 2hp 415 Vac 1
11 1 phase induction motor 1
12 Metal trunking 30 mm x30 mm As required
13 Self tapping Wood screw 4 mm x 20 mm As required
14 DIN rail 25 mm x 1mm
15 GI steel rigid conduit 20mm As required
16 Flexible conduit 20mm As required
17 End box 20 mm 4
18 Flexible wires 05 mm As required
19 Connectors 10 A As required
Procedures
1 Identify each components and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
4 Test the functionality of completed project
1 dead circuit 2 life circuit test
5 Record the current drawn by the load as connected in star and delta
Note Proper earthing should be made
53 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 8 INSPECTION AND TESTING OF ELECTRICAL INSTALLATION
On completion of a wiring installation a number of tests on the installation have to be conducted to
ascertain that the wiring circuits and connected appliances are safe for use Prior to carrying out the
tests an inspection has to be done The results of the inspectionsupervision and test have to be
presented in Form G (as in Appendix IV) and Form H (as in Appendix V)
To have the test certification as in Form H the following tests shall be conducted
i Continuity Test
ii Insulation Resistance Test
iii Polarity Test
iv Earth Electrode Resistance test and
v Residual Current Device Test
1 Continuity Test
There are 3 main types of continuity tests for the final circuits-
i Protection Conductor Continuity Test
ii Final Ring Circuit Conductor Continuity Test
iii Live and Neutral Conductor Continuity Test
a) Protection Conductor Continuity Test
bull To ascertain that all protection conductors are connected in the correct and effective manner
bull Test equipment ndash Multimeter (Ohm range) or Ohm meter
54 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
bull Test Method
1 1048766 Ensure that the main switch RCD and MCB are open circuited (switched off) and all loads
are disconnected
2 1048766 Connected the test leads as in the Figure 81 The meter reading shall be less than 1 Ω
55 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Final Ring Circuit Conductor Continuity Test
bull To ensure that all conductors around the ring circuit have continuity
bull Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
bull Test Method
1 1048766 Disconnect both the supply source live conductors from the MCB the neutral conductor
from the neutral terminals and the earth conductor from the earth terminal in the distribution
fuse box
2 1048766 Connect the test leads as in the Figure 82 (EE)
3 1048766 Repeat the procedure for (L-L) and (N-N)
4 1048766 The meter reading value shall be less than 1 ohm
56 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Live and Neutral Conductor Continuity Test
a To ensure that each conductor in the circuit has continuity
b Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
2 Test Method
1 1048766 Switch off the Main switch RCD and MCB
2 1048766 Disconnect all loads
3 1048766 Switch on all switches in the circuit
4 1048766 Disconnect the fusesfinal circuit breakers and close the circuit
5 1048766 Carry out the test as shown in Figure 83
6 1048766 The meter reading value shall be less than 1Ω
57 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
58 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
CONTINUITY TEST
Insulation Resistance Test
i Ensure that there is no leakage current between phase conductors phase and neutral conductors and
phase conductor and earth
ii Test the strength of the cable insulation
iii Test Equipment ndash Insulation Resistance Tester operating voltage is 250VDC or 500VDC
iv Test Method
1 1048766 Switch off main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
59 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
4 1048766 Carry out test as in the Table below
5 1048766 Meter reading value shall be less than 1 Megaohm
60 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
61 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Insulation resitance test
62 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
INSULATION RESISTANCE TEST BETWEEN CONDUCTORS AND OPPOSITE POLARITY
Polarity Testi Ensure that each fuse or single pole control and protection device is connected only in the phase
conductor
ii Intermediate contact of Edison screw lamp holder is connected to the phase conductor
iii Ensure that phase neutral and earth conductors at socket outlets are connected at the correct
terminals
iv Test Equipment ndash Multimeter (Ohm range) or Ohm meter
v Test Method
1 1048766 Switch off Main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in Figure 85
63 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
5 1048766 Test switches and single phase control devices at the phase conductors
6 1048766 Test socket outlet connection sources
7 1048766 Test Edison screw lamp holder connections
8 1048766 Meter reading value shall be less than 1 Ω
64 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Polarity test
65 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Earth Electrode Resistance Testi To test the earth electrode resistance
ii To ascertain the suitability of the location of the electrode
iii To ensure that the electrode is not buried within the resistance area of another electrode
iv Test equipment ndash Earth Resistance Tester
v Test method -
1 1048766 Terminal rsquoErsquo is connected to the electrode to be tested (green conductor)
2 1048766 Terminal lsquoPrsquo is connected to the potential spike (yellow conductor) at a distance of 10
meters from the earth electrode
3 1048766 Terminal lsquoCrsquo is connected to the current spike (red conductor) at a distance of 20 meters
from the earth electrode
Earth Electrode Resistance Measurement Method (Figure 86)
This test must be repeated at least three times to ensure that the reading is not affected by interacting
earthing regions
i Record the first reading (Z1) Example Z1 = 10 Ω
ii Move the voltage spike to a distance of 6 meters from the original position Record the second
reading (Z2 ) Example Z2 = 10 Ω
iii Move the voltage spike to a distance of 6 meters from the original position Record the third
reading (Z3) Example Z3 = 10 Ω
66 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Residual Current Device Testi Ensure that the residual current device (RCD) trips within the set time on the occurrence of current
leakage to earth
ii Test Equipment ndash RCD Tester RCCB Tester
iii Test Method 1
1 1048766 Use the Trip Test Button
2 1048766 Press the trip button found on the RCD to determine if it trips or otherwise This test would
not be able to determine the sensitivity of the RCD nor the time taken for it to trip
iv Test Method 2
i 1048766 Use a RCD Tester
ii This equipment is equipped with a 13A plug which can be connected to a 13A socket outlet
Select the RCD sensitivity to be the same as the sensitivity of the RCD to be tested to
determine if the RCD can trip The time to trip shall not exceed 40 mS
iii 1048766 Test method ndash
a) Position the selection switch in accordance with the sensitivity of the RCD used
Example 100 mA 01 A
b) Position the operations switch to lsquoNo Triprsquo (frac12 Rated mA = 50) connect the 3 pin plug to
the 13A socket outlet
67 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
c) Switch on the 13A socket outlet ndash ensure that the P-N and P-E lights light up
This shows that the polarity is correct (Note if both the lights as above do not light up the test cannot
be continued)
d) Press the test button ndash the reading shows less than 200 mS and simultaneously the lsquotestrsquo light lights
up and the P-N and P-E lights do not light up At that instant the RCD will not trip
e) Move the selection switch to 180o (+ve wave) ndash repeat steps (d) and (e) Move the operations
switch to lsquoTriprsquo (Rated mA = 100)
g) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200mS
h) Move the selection switch to 0o (-ve wave)
i) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
j) The above test is repeated until a near correct reading is obtained
k) Record the test results
l) Change the operations switch to lsquoFast Triprsquo and press the test button ndash RCD will trip within a
time not exceeding 40 millisecond
m) Repeat a number of times at 0o or 180o
On completion of a wiring installation a number of tests on the installation have to be conducted to
ascertain that the wiring circuits and connected appliances are safe for use Prior to carrying out the
tests an inspection has to be done the following tests shall be conducted
i Continuity Test
ii Insulation Resistance Test
iii Polarity Test
iv Earth Electrode Resistance test and
v Residual Current Device Test
821 Continuity Test
There are 3 main types of continuity tests for the final circuits-
i Protection Conductor Continuity Test
ii Final Ring Circuit Conductor Continuity Test
68 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
iii Live and Neutral Conductor Continuity Test
a) Protection Conductor Continuity Test
bull To ascertain that all protection conductors are connected in the correct and effective manner
bull Test equipment ndash Multimeter (Ohm range) or Ohm meter
bull Test Method
1 1048766 Ensure that the main switch RCD and MCB are open circuited (switched off) and all loads are
disconnected
2 1048766 Connected the test leads as in the Figure 81
3 1048766 The meter reading shall be less than 1 Ω
Final Ring Circuit Conductor Continuity Test
bull To ensure that all conductors around the ring circuit have continuity
bull Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
bull Test Method
1 1048766 Disconnect both the supply source live conductors from the MCB the neutral conductor
from the neutral terminals and the earth conductor from the earth terminal in the distribution
fuse box
2 1048766 Connect the test leads as in the Figure 82 (EE)
3 1048766 Repeat the procedure for (L-L) and (N-N)
4 1048766 The meter reading value shall be less than 1 ohm Figure 82 - Final Ring Circuit Conductor
Continuity Test Ohm Meter
Disconnect both the supply source cables from mcbfuse
Take readings at earth conductors of both sources and note resistance readings
Live and Neutral Conductor Continuity Test
1 To ensure that each conductor in the circuit has continuity
2 Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
3 Test Method
1 1048766 Switch off the Main switch RCD and MCB
2 1048766 Disconnect all loads
3 1048766 Switch on all switches in the circuit
4 1048766 Disconnect the fusesfinal circuit breakers and close the circuit
5 1048766 Carry out the test as shown in Figure 83
6 1048766 The meter reading value shall be less than 1 ohm Figure 83 - Live and Neutral
Conductor Continuity Test Ohm Meter
Insulation Resistance Test
69 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
i Ensure that there is no leakage current between phase conductors phase and neutral conductors and
phase conductor and earth
ii Test the strength of the cable insulation
iii Test Equipment ndash Insulation Resistance Tester Operating voltage is 250VDC or 500VDC
iv Test Method
1 1048766 Switch off main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in the Table below
5 1048766 Meter reading value shall be less than 1 Megaohm
Polarity Test
i Ensure that each fuse or single pole control and protection device is connected only in the phase
conductor
ii Intermediate contact of Edison screw lamp holder is connected to the phase conductor
iii Ensure that phase neutral and earth conductors at socket outlets are connected at the correct
terminals
iv Test Equipment ndash Multimeter (Ohm range) or Ohm meter
v Test Method
1 1048766 Switch off Main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in Figure 85
5 1048766 Test switches and single phase control devices at the phase conductors
6 1048766 Test socket outlet connection sources
7 1048766 Test Edison screw lamp holder connections
8 1048766 Meter reading value shall be less than 1 Ω
Earth Electrode Resistance Test
i To test the earth electrode resistance
70 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
ii To ascertain the suitability of the location of the electrode
iii To ensure that the electrode is not buried within the resistance area of another electrode
iv Test equipment ndash Earth Resistance Tester
v Test method -
1 1048766 Terminal rsquoErsquo is connected to the electrode to be tested (green conductor)
2 1048766 Terminal lsquoPrsquo is connected to the potential spike (yellow conductor) at a distance of 10
meters from the earth electrode
3 1048766 Terminal lsquoCrsquo is connected to the current spike (red conductor) at a distance of 20 meters
from the earth electrode E P C Electrode 10 meter 10 meter
Figure 86 ndash Earth Electrode Resistance Measurement Test Equipment
Earth Electrode Resistance Measurement Method (Figure 86)
This test must be repeated at least three times to ensure that the reading is not affected by interacting
earthing regions
i Record the first reading (Z1) Example Z1 = 10 Ω
ii Move the voltage spike to a distance of 6 meters from the original position Record the second
reading (Z2) Example Z2 = 10 Ω
iii Move the voltage spike to a distance of 6 meters from the original position Record the third
reading (Z3)
Example Z3 = 10 Ω
Residual Current Device Test
71 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
i Ensure that the residual current device (RCD) trips within the set time on the occurrence of current
leakage to earth
ii Test Equipment ndash RCD Tester RCCB Tester
iii Test Method 1
1 1048766 Use the Trip Test Button
2 1048766 Press the trip button found on the RCD to determine if it trips or otherwise This test would
not be able to determine the sensitivity of the RCD nor the time taken for it to trip
iv Test Method 2
1048766 Use a RCD Tester
This equipment is equipped with a 13A plug which can be connected to a 13A socket outlet Select the
RCD sensitivity to be the same as the sensitivity of the RCD to be tested to determine if the RCD can
trip The time to trip shall not exceed 40 mS
1048766 Test method ndash
a) Position the selection switch in accordance with the sensitivity of the RCD used
Example 100 mA 01 A
b) Position the operations switch to lsquoNo Triprsquo (frac12 Rated mA = 50) connect the 3 pin plug to
the 13A socket outlet
c) Switch on the 13A socket outlet ndash ensure that the P-N and P-E lights light up This shows that
the polarity is correct (Note if both the lights as above do not light up the test cannot be
continued)
d) Press the test button ndash the reading shows less than 200 millisecond and simultaneously the
lsquotestrsquo light lights up and the P-N and P-E lights do not light up At that instant the RCD will
not trip
e) Move the selection switch to 180o (+ve wave) ndash repeat steps (d) and (e) = 100)
f) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
g) Move the selection switch to 0o (-ve wave)
h) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
i) The above test is repeated until a near correct reading is obtained
j) Record the test results
k) Change the operations switch to lsquoFast Triprsquo and press the test button ndash RCD will trip within a
time not exceeding 40 mS
l) Repeat a number of times at 0o or 180o
72 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 9 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (DC)
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
73 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Start stop button 240Vac 5A 2
9 Filament lamp (Bulb ) 240Vac 40W 3
10 Overload Relay 415V 20A 3
11 Three phase induction motor 5 hp 3
12 Single phase step down transformer 2500VA 1
13 Single core PVC insulated Cable 1mm 2 As required
14 Single core PVC insulated Cable 25mm 2 As required
15 DIN rail 35 mm As required
16 PVC type Cable tray 50 mm x 50 mm As required
17 Cable ties 4 ldquo As required
18 Flexible wires 05 mm As required
19 PVC Connectors 5 A amp 20 A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the schematic
diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a optional exercise
i Simple DOL starter
ii Forward reverse DOL starter
iii Forward Reverse Dahlander motor
iv Three motors operated in sequence by DOL starter operated by manual push
button or time delay relay
74 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
a One loop per-cycle
b Continuous operation in a loop
c optional circuit design to represent the same task
v Only one out of three motors to be operated at a time (quiz)
4 Test the functionality of completed project
LESSON 10 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (AC)
75 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 1
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Lamp point 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
76 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
11 Overload Relay 415V 20A 3
12 Three phase induction
motor
5 hp 3
13 Single core PVC insulated
Cable
1mm 2 As required
14 Single core PVC insulated
Cable
25mm 2 As required
15 DIN rail 35 mm As required
16 PVC type Cable tray 50 mm x 50 mm As required
17 Cable ties 4 ldquo As required
18 Flexible wires 05 mm As required
19 PVC Connectors 5 A amp 20 A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the
schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram optional exercise
4 Simple DOL starter
5 Forward reverse DOL starter
6 Test the functionality of completed project
77 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 1
78 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
cm
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Indicating light 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
11 Overload Relay 415V 20A 3
12 Three phase induction motor 5 hp 3
13 Single phase step down
transformer
2500VA 1
14 Single core PVC insulated
Cable
1mm 2 As required
15 Single core PVC insulated
Cable
25mm 2 As required
16 DIN rail 35 mm As required
17 PVC type Cable tray 50 mm x 50 mm As required
18 Cable ties 4 ldquo As required
19 Flexible wires 05 mm As required
20 PVC Connectors 5 A amp 20 A 240 V As required
21 Single pole MCB 6A 240 V 1
22 Single pole MCB 2A 240 V 1
23 Triple pole MCB 20A 415 V 1
24 Mounting board 30 cm x 40 cm x 3
cm
1
25 Relay cw 11 pin socket 10 A 240 Vac 2
26 Time delay relay 10 A 240 Vac 3
27 Triple pole Contactor 20A 240Vac 3
28 Batten type Lamp holder 240Vac 10 A 3
29 Start stop button 240Vac 10A 2
30 Indicating light (Bulb ) 240Vac 25W 3
31 Overload Relay 415V 20A 1
32 Three phase dahlander type
induction motor
5 hp 1
33 Single phase step down
transformer
24024Vac
2500VA
1
79 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
34 Single core PVC insulated
Cable
1mm 2 As required
35 Single core PVC insulated
Cable
25mm 2 As required
36 DIN rail 35 mm As required
37 PVC type Cable tray 50 mm x 50 mm As required
38 Cable ties 4 ldquo As required
39 Flexible wires 075 mm As required
40 PVC Connectors 5 A amp 20 A 240 V As required
41 Terminal block 20A 240Vac As required
Procedures
5 Identify each component according to specification and quantity required from the schematic
diagram attached
6 Test the functionality of each component by using multi-meter or power supply whichever
applicable
7 Wire component according to circuit diagram
8 Three motors operated in sequence by DOL starter operated by manual push button or time
delay relay
a One loop per-cycle
b Continuous operation in a loop
c optional circuit design to represent the same task
d Only one out of three motors to be operated at a time (quiz)
9 Test the functionality of completed project
80 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
BASIC DESIGN INDUSTRIAL MOTOR CONTROL (SEQUENCE CONTROL)
THREE PHASE INDUCTION MOTOR OPERATED IN SEQUENCE BY DIRECT ON LINE
STARTER
LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
81 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
82 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Lcd lamp indicator 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
11 Overload Relay 415V 20A 3
12 Three phase induction motor 5 hp 3
13 Single phase step down transformer 2500VA 1
14 Single core PVC insulated Cable 1mm 2 As required
15 Single core PVC insulated Cable 25mm 2 As required
16 DIN rail 35 mm As required
17 PVC type Cable tray 50 mm x 50 mm As required
18 Cable ties 4 ldquo As required
19 Flexible wires 1 mm Oslash As required
20 PVC Terminal block 10A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the schematic
diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a optional exercise
i Forward Reverse dahlander motor
4 Test the functionality of completed project
83 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
THREE PHASE DAHLANDER TYPE INDUCTION MOTOR OPERATED FORWARD AND
REVERSE OPERATION BY DIRECT ON LINE STARTER
84 ndash 99EASYTECH ENTERPRISE
LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
Introduction
If a motors windings are connected in the star configuration any two phases will be in series across
the supply and hence the line current will be smaller(by 577) than if the windings were connected in
the delta arrangement
Hence larger-type motors with heavy starting currents are first connected in star and then when the
starting currents fall in delta This of course means that all six of the ends of the windings must be
brought to terminations outside the casing (Fig 833)
EZTECH
EZTECH ELECTRICAL INSTALLATION GUIDE
The automatic version of this starter incorporates a timing relay which automatically changes the
connections from star to delta Figs 834 and 835 show the wiring and schematic diagrams for a star
delta starter
Objectives
1 Identify component and the specification
2 Design forward reverse star delta starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
2 ndash 99EASYTECH ENTERPRISE
REV -C
LEGENDMCCB Moulded Case Circuit BreakerTOR Thermal Over Load RelayFOW-C Mains Forward ContactorREV-C Mains Reverse ContactorDC Delta ContactorSC Star ContactorS-SW Mains Selector Switch
SC
V2
W2
U2
DC
V1
W1
U1
TOR
TOR
FOW-C
30A MCCB
TOR
MAIN CIRCUIT FORWARD REVERSE STAR DELTA
RYBN S
-SW
3 PHASEINDUCTION MOTOR
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Relay 10 A 240V 3
5 Triple pole Contactor
6 cw NO NC auxiliary contact
240Vac 20 A 4
7 Overload Relay 415 V 1
8 LED indicator 240vac 5 A 4
9 Start stop button 240Vac 5A 2
10 DIN rail 35 mm As required
11 Flexible wires 1 mm As required
12 Single core PVC insulated
wire
25 mm As required
13 Terminal block 20 A As required
14 Squirrel cage motor 5kW 1
15 5 pin plug and socket 415V 20A 1
16 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
3 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
a Manual star delta
b Manual Forward reverse star delta starter
c Automatic star delta starter
d Automatic Forward reverse star delta starter
4 Test the functionality of completed project
4 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
Objectives
1 Identify component and the specification
2 Design auto transformer starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
5 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Autotransformer starter is used to start a 3 phase induction motor that has a rating between 10 to 15 hp
6 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Autotransformer set 10Kw 415 V 50 Hz 1
5 Triple pole Contactor 240Vac 4
6 Batten type Lamp holder 240 Vac 105 A 4
7 Start stop button 240Vac 10A 4
8 Filament lamp (Bulb ) 240Vac 40W 4
9 DIN rail 35 mm As required
10 Flexible wires 1 mm As required
7 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
11 Single core PVC insulated
wire
25 mm As required
12 Terminal block 20 A As required
13 Squirrel cage motor 10kW 1
14 5 pin plug and socket 415V 20A 1
15 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a open transient autotransformer starter
b close transient autotransformer starter
c Forward reverse autotransformer starter
4 Test the functionality of completed project
8 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
Objectives
1 Identify component and the specification
2 Design rotor resistance starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
9 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Rotor Resistor set 10kW 1
5 Triple pole Contactor 240Vac 20A 4
6 Indicating light 240vac 5 A 4
7 Start stop push button 240Vac 5A 4
8 DIN rail 35 mm As required
9 Flexible wires 1 mm 2 As required
10 Single core PVC insulated wire 25 mm 2 As required
11 Terminal block 20 A As required
12 Slip Ring motor 10kW 1
13 5 pin round 3 phase socket 415V 20A 1
14 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
10 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
4 Test the functionality of completed project
a Dead circuit test b Life circuit test
5 Measure starting and running Amps
LESSON 16
TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
An installation in general will suffer damage
Damage usually occurs on the electric motor control as follows
1 Damage to the main circuit
2 Damage to the control circuit
The cause of the damage
i Overcurrent overload short circuit
ii Leakage current to ground
iii Equipment malfunction
iv The main control circuit
a Trip of main circuit protection devices fire
b Defect of motor terminal such as short circuit fire loose
v The control circuit is not functioning -
a contactor relay relay time overload relay does not work damaged burned
b Loose cable connection disconnected
Detecting and Repairing Damage
Examples of damage are as follows
i Motor does not work
ii Motor function and overload relay trips
iii Motor function but only partially functional control circuit
Methods of detecting damage
Among the known methods necessary to detect damage are as follows
1 Turn off the electricity at the main switch (main switch) in order to avoid any danger during the
work carried out to detect damage
2 Check all the protective gear that controls the motor control main circuit
11 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
3 Make sure the damage function control circuit
4 Check the control circuit according to the schematic circuit diagram of the motor control
5 Check the operation of the control circuit
Note
Use wiring that has been installed on the SYSTEM OF MOTOR CONTROL BOARD by Forward
Reverse control circuit for Star Delta to test and look for damage
SELF-ASSESSMENT QUESTIONS
1 (a) Explain what is meant by the term lsquoback emfrsquo in a motor
(b) Outline the basic differences between series shunt and compound wound dc motors
2 (a) With the aid of diagrams explain how the speed of series shunt and compound-wound motors
may be controlled
(b) A 440V dc shunt-wound motor has a field resistance of 200R and an armature resistance of 06 R
When its speed is 20 rev d second the current drawn from the supply is 122A Calculate its back
emf at this speed If the speed were decreased to 19 revssecond the field flux remaining unchanged
calculate the new back emf and the new armature current
3 A load of 64 kW at 240 V is supplied from the terminals of a shunt-wound dc generator The field
resistance is 180 A Calculate the armature current
4 (a) Explain with the aid of a diagram how a rotating magnetic field may be
(b) What is meant by lsquosynchronous speedrsquo
Calculate the synchronous obtained speed of a 12 pole motor if the supply frequency is 50Hz
5 (a) Explain the action of a synchronous motor
(b) What methods are available to start a synchronous motor Explain with diagrams
6 (a) Explain the action of a cage induction motor
(b) What is meant by the term lsquosliprsquo
Calculate the percentage slip of a six pole induction motor running at 162 revssecond from a 50 Hz
supply
7 Describe with sketches three different ways of starting a single-phase induction motor
12 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
8 Explain with the aid of a sketch the action of a three-phase DOL starter
What are dashpots used for How are remote start and stop buttons connected
9 A I0 kW 240V 50Hz single-phase cage rotor induction motor is 85efficient and has a PF of 068
lagging Calculate the motor current and the value of capacitor required to raise the PF to 093
lagging
10 Calculate the torque developed by an 18 kW four-pole induction motor run at 35 slip from a
50Hz supply
APPENDIX 1
13 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 11
14 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 111
Attachment Reference
httpswwwtlc-directcoukBook621htm
httpwwwstgovmyindexphpms
15 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 5 ndashWIRING SYSTEM OF 1 Oslash LIGHTING AND POWER CIRCUIT
POWER CIRCUITSa Radial circuits
Radial circuits are arranged in the same way as item 1 above in lighting layouts in that each socket
outlet is supplied via the previous one
Points to note
1 The number of socket outlets complying with BS 1363 is unlimited for a floor area of up to 50m 2 if
the circuit protection is a 30 A or 32 A cartridge fuse or circuit breaker the cable being 4 mm PVC
copper or 25 mm2 mineral insulated (mi)
2 The number of socket outlets is unlimited for a floor area up to 20 m 2 with any type of circuit
protection of 20 A using 25 mm2 PVC copper cable or 15 mm2 mi
3 The total number of fused spurs is unlimited
b ring final circuits
These circuits are the same as radial circuits except that the final socket outlet is wired back to the
supply position In effect any outlet is supplied from two directions (Fig 152)
Points to note
1 Every twin-socket outlet counts as two single-socket outlets
2 The number of non-fused spurs must not exceed the total number of points on the ring Fig 158
shows seven points on the ring and five spurs
3 The fuse rating of a fused spur box must not exceed 13 A and the current rating of all points supplied
by the fused spur must not exceed 13 A
4 Non-fused spurs must supply no more than one single or one double socket on the ring Fig 158
shows seven points on the ring and five spurs rating of all points supplied by the fused spur must not
exceed 13 A or one stationary appliance
CapacityMain conductor size
copper (mm2)
Earth conductor
size (mm2)
Circuit breaker
capacity (A)
Up to 600 W 15 15 6
600ndash1200 W 1525 15 10
1200ndash1800 W 254 25 16
41 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Ring circuit
(floor area 100 m2)25 15 3032
A2 radial circuit
(floor area 75 m2)40 25 3032
A3 radial circuit
(floor area 50 m2)25 15 20
Air conditioner (15 tonne) 60 60 3032
Cooker 60 60 3032
Water heater 40 40 20
Objectives
1 Identify component and the specification
2 Wire component according to the schematic diagram
3 Test the functionality of the circuit
42 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board Perforated 1
2 Cut out fuse and neutral link 60A 240V 1each
3 kWh meter 240V 40A 1
4 Switched Socket outlet 13A 240Vac 4
5 Single pole two way switch cw switch
box
5A 240Vac 2
6 RCCB ELCB 63 A Tripping current 100mA
415 Vac
1
7 3 pin plug 240Vac 13A 4
8 Single pole MCB 20 A 2
9 Single pole MCB 6A 1
10 Single pole MCB 20A 2
11 DOL starter 240Vac 2
12 1 phase induction motor 2hp 240 Vac 1
13 Self tapping Wood screw As required
14 DIN rail Stainless steel allum35 mm As required
15 PVC pipe 20mm dia As required
16 End box 20 mm dia 4
17 Flexible wires 05 mm 2 As required
18 Connectors 5 A As required
Procedures
43 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
4 Test the functionality of completed project
LESSON 6 ndash WIRING SYSTEM OF 3 Oslash DISTRIBUTION BOARD
Introduction
44 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
45 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
46 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
47 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
48 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify each component and the specification
2 Wire component according to the schematic diagram given
3 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting Board 450 x 600 mm Perforated metal 1
2 5 pin round socket and plug 415V ac 32A 1
3 Cut out fuse 60 A 3
4 Neutral link 1
5 kWatt hour meter 415V 60A 1
6 ELCB RCCB 3P+N In=63A415 Vac I trip= 300mA 1
7 ELCB RCCB 3P+N In=63A415 Vac I trip= 30mA 1
8 Single pole MCB 6A 240 V 3
9 Single pole MCB 20A 240 V 3
10 DOL starter 20 A 240Vac 2
11 Socket outlet 15 A 240 Vac 1
12 Switched Socket outlet 13 A 240 Vac 3
13 Led indicating light 5A 240 Vac 3
14 Single pole 4 gang 1 way switch 5A 240 Vac 2
15 Single pole 2 way switch 5A 240 Vac 2
16 1 phase induction motor 1 kW 240Vac 1
17 Metal trunking 30 mm x30 mm As required
18 Self tapping Wood screw 4 mm x 20 mm As required
19 DIN rail 25 mm x 1mm
20 GI steel rigid conduit 20mm As required
21 Flexible conduit 20mm As required
22 End box 20 mm 4
23 Flexible wires 05 mm 2 As required
24 Single core PVC insulated wire 15 mm 2 As required
25 Single core PVC insulated wires 25 mm 2 As required
26 Terminal block 10 A As required
Procedures
49 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify each components and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
4 Test the functionality of completed project
1 dead circuit test
2 life circuit
Note Proper earthing should be made
50 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 7 ndash WIRING SYSTEM OF THREE PHASE LIGHTING AND POWER CIRCUIT
51 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
52 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify component and the specification
2 Wire component according to the schematic diagram
3 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting bay Board Perforated metal 180 cm x 180 cm 1
2 k Watt hour meter 415V 60A 1
3 MCCB 415V 60A
4 ELCB RCCB In=60A415 Vac I trip=30mA 1
5 5 pin round Socket and
plug
415Vac 32A 4
6 Single pole MCB 6A 1
7 Triple pole MCB 20A 2
8 Triple pole Main switch 60A 1
9 DOL starter 240Vac 2
10 3 phase induction motor 2hp 415 Vac 1
11 1 phase induction motor 1
12 Metal trunking 30 mm x30 mm As required
13 Self tapping Wood screw 4 mm x 20 mm As required
14 DIN rail 25 mm x 1mm
15 GI steel rigid conduit 20mm As required
16 Flexible conduit 20mm As required
17 End box 20 mm 4
18 Flexible wires 05 mm As required
19 Connectors 10 A As required
Procedures
1 Identify each components and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
4 Test the functionality of completed project
1 dead circuit 2 life circuit test
5 Record the current drawn by the load as connected in star and delta
Note Proper earthing should be made
53 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 8 INSPECTION AND TESTING OF ELECTRICAL INSTALLATION
On completion of a wiring installation a number of tests on the installation have to be conducted to
ascertain that the wiring circuits and connected appliances are safe for use Prior to carrying out the
tests an inspection has to be done The results of the inspectionsupervision and test have to be
presented in Form G (as in Appendix IV) and Form H (as in Appendix V)
To have the test certification as in Form H the following tests shall be conducted
i Continuity Test
ii Insulation Resistance Test
iii Polarity Test
iv Earth Electrode Resistance test and
v Residual Current Device Test
1 Continuity Test
There are 3 main types of continuity tests for the final circuits-
i Protection Conductor Continuity Test
ii Final Ring Circuit Conductor Continuity Test
iii Live and Neutral Conductor Continuity Test
a) Protection Conductor Continuity Test
bull To ascertain that all protection conductors are connected in the correct and effective manner
bull Test equipment ndash Multimeter (Ohm range) or Ohm meter
54 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
bull Test Method
1 1048766 Ensure that the main switch RCD and MCB are open circuited (switched off) and all loads
are disconnected
2 1048766 Connected the test leads as in the Figure 81 The meter reading shall be less than 1 Ω
55 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Final Ring Circuit Conductor Continuity Test
bull To ensure that all conductors around the ring circuit have continuity
bull Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
bull Test Method
1 1048766 Disconnect both the supply source live conductors from the MCB the neutral conductor
from the neutral terminals and the earth conductor from the earth terminal in the distribution
fuse box
2 1048766 Connect the test leads as in the Figure 82 (EE)
3 1048766 Repeat the procedure for (L-L) and (N-N)
4 1048766 The meter reading value shall be less than 1 ohm
56 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Live and Neutral Conductor Continuity Test
a To ensure that each conductor in the circuit has continuity
b Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
2 Test Method
1 1048766 Switch off the Main switch RCD and MCB
2 1048766 Disconnect all loads
3 1048766 Switch on all switches in the circuit
4 1048766 Disconnect the fusesfinal circuit breakers and close the circuit
5 1048766 Carry out the test as shown in Figure 83
6 1048766 The meter reading value shall be less than 1Ω
57 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
58 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
CONTINUITY TEST
Insulation Resistance Test
i Ensure that there is no leakage current between phase conductors phase and neutral conductors and
phase conductor and earth
ii Test the strength of the cable insulation
iii Test Equipment ndash Insulation Resistance Tester operating voltage is 250VDC or 500VDC
iv Test Method
1 1048766 Switch off main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
59 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
4 1048766 Carry out test as in the Table below
5 1048766 Meter reading value shall be less than 1 Megaohm
60 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
61 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Insulation resitance test
62 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
INSULATION RESISTANCE TEST BETWEEN CONDUCTORS AND OPPOSITE POLARITY
Polarity Testi Ensure that each fuse or single pole control and protection device is connected only in the phase
conductor
ii Intermediate contact of Edison screw lamp holder is connected to the phase conductor
iii Ensure that phase neutral and earth conductors at socket outlets are connected at the correct
terminals
iv Test Equipment ndash Multimeter (Ohm range) or Ohm meter
v Test Method
1 1048766 Switch off Main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in Figure 85
63 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
5 1048766 Test switches and single phase control devices at the phase conductors
6 1048766 Test socket outlet connection sources
7 1048766 Test Edison screw lamp holder connections
8 1048766 Meter reading value shall be less than 1 Ω
64 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Polarity test
65 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Earth Electrode Resistance Testi To test the earth electrode resistance
ii To ascertain the suitability of the location of the electrode
iii To ensure that the electrode is not buried within the resistance area of another electrode
iv Test equipment ndash Earth Resistance Tester
v Test method -
1 1048766 Terminal rsquoErsquo is connected to the electrode to be tested (green conductor)
2 1048766 Terminal lsquoPrsquo is connected to the potential spike (yellow conductor) at a distance of 10
meters from the earth electrode
3 1048766 Terminal lsquoCrsquo is connected to the current spike (red conductor) at a distance of 20 meters
from the earth electrode
Earth Electrode Resistance Measurement Method (Figure 86)
This test must be repeated at least three times to ensure that the reading is not affected by interacting
earthing regions
i Record the first reading (Z1) Example Z1 = 10 Ω
ii Move the voltage spike to a distance of 6 meters from the original position Record the second
reading (Z2 ) Example Z2 = 10 Ω
iii Move the voltage spike to a distance of 6 meters from the original position Record the third
reading (Z3) Example Z3 = 10 Ω
66 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Residual Current Device Testi Ensure that the residual current device (RCD) trips within the set time on the occurrence of current
leakage to earth
ii Test Equipment ndash RCD Tester RCCB Tester
iii Test Method 1
1 1048766 Use the Trip Test Button
2 1048766 Press the trip button found on the RCD to determine if it trips or otherwise This test would
not be able to determine the sensitivity of the RCD nor the time taken for it to trip
iv Test Method 2
i 1048766 Use a RCD Tester
ii This equipment is equipped with a 13A plug which can be connected to a 13A socket outlet
Select the RCD sensitivity to be the same as the sensitivity of the RCD to be tested to
determine if the RCD can trip The time to trip shall not exceed 40 mS
iii 1048766 Test method ndash
a) Position the selection switch in accordance with the sensitivity of the RCD used
Example 100 mA 01 A
b) Position the operations switch to lsquoNo Triprsquo (frac12 Rated mA = 50) connect the 3 pin plug to
the 13A socket outlet
67 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
c) Switch on the 13A socket outlet ndash ensure that the P-N and P-E lights light up
This shows that the polarity is correct (Note if both the lights as above do not light up the test cannot
be continued)
d) Press the test button ndash the reading shows less than 200 mS and simultaneously the lsquotestrsquo light lights
up and the P-N and P-E lights do not light up At that instant the RCD will not trip
e) Move the selection switch to 180o (+ve wave) ndash repeat steps (d) and (e) Move the operations
switch to lsquoTriprsquo (Rated mA = 100)
g) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200mS
h) Move the selection switch to 0o (-ve wave)
i) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
j) The above test is repeated until a near correct reading is obtained
k) Record the test results
l) Change the operations switch to lsquoFast Triprsquo and press the test button ndash RCD will trip within a
time not exceeding 40 millisecond
m) Repeat a number of times at 0o or 180o
On completion of a wiring installation a number of tests on the installation have to be conducted to
ascertain that the wiring circuits and connected appliances are safe for use Prior to carrying out the
tests an inspection has to be done the following tests shall be conducted
i Continuity Test
ii Insulation Resistance Test
iii Polarity Test
iv Earth Electrode Resistance test and
v Residual Current Device Test
821 Continuity Test
There are 3 main types of continuity tests for the final circuits-
i Protection Conductor Continuity Test
ii Final Ring Circuit Conductor Continuity Test
68 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
iii Live and Neutral Conductor Continuity Test
a) Protection Conductor Continuity Test
bull To ascertain that all protection conductors are connected in the correct and effective manner
bull Test equipment ndash Multimeter (Ohm range) or Ohm meter
bull Test Method
1 1048766 Ensure that the main switch RCD and MCB are open circuited (switched off) and all loads are
disconnected
2 1048766 Connected the test leads as in the Figure 81
3 1048766 The meter reading shall be less than 1 Ω
Final Ring Circuit Conductor Continuity Test
bull To ensure that all conductors around the ring circuit have continuity
bull Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
bull Test Method
1 1048766 Disconnect both the supply source live conductors from the MCB the neutral conductor
from the neutral terminals and the earth conductor from the earth terminal in the distribution
fuse box
2 1048766 Connect the test leads as in the Figure 82 (EE)
3 1048766 Repeat the procedure for (L-L) and (N-N)
4 1048766 The meter reading value shall be less than 1 ohm Figure 82 - Final Ring Circuit Conductor
Continuity Test Ohm Meter
Disconnect both the supply source cables from mcbfuse
Take readings at earth conductors of both sources and note resistance readings
Live and Neutral Conductor Continuity Test
1 To ensure that each conductor in the circuit has continuity
2 Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
3 Test Method
1 1048766 Switch off the Main switch RCD and MCB
2 1048766 Disconnect all loads
3 1048766 Switch on all switches in the circuit
4 1048766 Disconnect the fusesfinal circuit breakers and close the circuit
5 1048766 Carry out the test as shown in Figure 83
6 1048766 The meter reading value shall be less than 1 ohm Figure 83 - Live and Neutral
Conductor Continuity Test Ohm Meter
Insulation Resistance Test
69 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
i Ensure that there is no leakage current between phase conductors phase and neutral conductors and
phase conductor and earth
ii Test the strength of the cable insulation
iii Test Equipment ndash Insulation Resistance Tester Operating voltage is 250VDC or 500VDC
iv Test Method
1 1048766 Switch off main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in the Table below
5 1048766 Meter reading value shall be less than 1 Megaohm
Polarity Test
i Ensure that each fuse or single pole control and protection device is connected only in the phase
conductor
ii Intermediate contact of Edison screw lamp holder is connected to the phase conductor
iii Ensure that phase neutral and earth conductors at socket outlets are connected at the correct
terminals
iv Test Equipment ndash Multimeter (Ohm range) or Ohm meter
v Test Method
1 1048766 Switch off Main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in Figure 85
5 1048766 Test switches and single phase control devices at the phase conductors
6 1048766 Test socket outlet connection sources
7 1048766 Test Edison screw lamp holder connections
8 1048766 Meter reading value shall be less than 1 Ω
Earth Electrode Resistance Test
i To test the earth electrode resistance
70 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
ii To ascertain the suitability of the location of the electrode
iii To ensure that the electrode is not buried within the resistance area of another electrode
iv Test equipment ndash Earth Resistance Tester
v Test method -
1 1048766 Terminal rsquoErsquo is connected to the electrode to be tested (green conductor)
2 1048766 Terminal lsquoPrsquo is connected to the potential spike (yellow conductor) at a distance of 10
meters from the earth electrode
3 1048766 Terminal lsquoCrsquo is connected to the current spike (red conductor) at a distance of 20 meters
from the earth electrode E P C Electrode 10 meter 10 meter
Figure 86 ndash Earth Electrode Resistance Measurement Test Equipment
Earth Electrode Resistance Measurement Method (Figure 86)
This test must be repeated at least three times to ensure that the reading is not affected by interacting
earthing regions
i Record the first reading (Z1) Example Z1 = 10 Ω
ii Move the voltage spike to a distance of 6 meters from the original position Record the second
reading (Z2) Example Z2 = 10 Ω
iii Move the voltage spike to a distance of 6 meters from the original position Record the third
reading (Z3)
Example Z3 = 10 Ω
Residual Current Device Test
71 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
i Ensure that the residual current device (RCD) trips within the set time on the occurrence of current
leakage to earth
ii Test Equipment ndash RCD Tester RCCB Tester
iii Test Method 1
1 1048766 Use the Trip Test Button
2 1048766 Press the trip button found on the RCD to determine if it trips or otherwise This test would
not be able to determine the sensitivity of the RCD nor the time taken for it to trip
iv Test Method 2
1048766 Use a RCD Tester
This equipment is equipped with a 13A plug which can be connected to a 13A socket outlet Select the
RCD sensitivity to be the same as the sensitivity of the RCD to be tested to determine if the RCD can
trip The time to trip shall not exceed 40 mS
1048766 Test method ndash
a) Position the selection switch in accordance with the sensitivity of the RCD used
Example 100 mA 01 A
b) Position the operations switch to lsquoNo Triprsquo (frac12 Rated mA = 50) connect the 3 pin plug to
the 13A socket outlet
c) Switch on the 13A socket outlet ndash ensure that the P-N and P-E lights light up This shows that
the polarity is correct (Note if both the lights as above do not light up the test cannot be
continued)
d) Press the test button ndash the reading shows less than 200 millisecond and simultaneously the
lsquotestrsquo light lights up and the P-N and P-E lights do not light up At that instant the RCD will
not trip
e) Move the selection switch to 180o (+ve wave) ndash repeat steps (d) and (e) = 100)
f) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
g) Move the selection switch to 0o (-ve wave)
h) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
i) The above test is repeated until a near correct reading is obtained
j) Record the test results
k) Change the operations switch to lsquoFast Triprsquo and press the test button ndash RCD will trip within a
time not exceeding 40 mS
l) Repeat a number of times at 0o or 180o
72 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 9 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (DC)
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
73 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Start stop button 240Vac 5A 2
9 Filament lamp (Bulb ) 240Vac 40W 3
10 Overload Relay 415V 20A 3
11 Three phase induction motor 5 hp 3
12 Single phase step down transformer 2500VA 1
13 Single core PVC insulated Cable 1mm 2 As required
14 Single core PVC insulated Cable 25mm 2 As required
15 DIN rail 35 mm As required
16 PVC type Cable tray 50 mm x 50 mm As required
17 Cable ties 4 ldquo As required
18 Flexible wires 05 mm As required
19 PVC Connectors 5 A amp 20 A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the schematic
diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a optional exercise
i Simple DOL starter
ii Forward reverse DOL starter
iii Forward Reverse Dahlander motor
iv Three motors operated in sequence by DOL starter operated by manual push
button or time delay relay
74 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
a One loop per-cycle
b Continuous operation in a loop
c optional circuit design to represent the same task
v Only one out of three motors to be operated at a time (quiz)
4 Test the functionality of completed project
LESSON 10 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (AC)
75 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 1
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Lamp point 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
76 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
11 Overload Relay 415V 20A 3
12 Three phase induction
motor
5 hp 3
13 Single core PVC insulated
Cable
1mm 2 As required
14 Single core PVC insulated
Cable
25mm 2 As required
15 DIN rail 35 mm As required
16 PVC type Cable tray 50 mm x 50 mm As required
17 Cable ties 4 ldquo As required
18 Flexible wires 05 mm As required
19 PVC Connectors 5 A amp 20 A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the
schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram optional exercise
4 Simple DOL starter
5 Forward reverse DOL starter
6 Test the functionality of completed project
77 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 1
78 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
cm
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Indicating light 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
11 Overload Relay 415V 20A 3
12 Three phase induction motor 5 hp 3
13 Single phase step down
transformer
2500VA 1
14 Single core PVC insulated
Cable
1mm 2 As required
15 Single core PVC insulated
Cable
25mm 2 As required
16 DIN rail 35 mm As required
17 PVC type Cable tray 50 mm x 50 mm As required
18 Cable ties 4 ldquo As required
19 Flexible wires 05 mm As required
20 PVC Connectors 5 A amp 20 A 240 V As required
21 Single pole MCB 6A 240 V 1
22 Single pole MCB 2A 240 V 1
23 Triple pole MCB 20A 415 V 1
24 Mounting board 30 cm x 40 cm x 3
cm
1
25 Relay cw 11 pin socket 10 A 240 Vac 2
26 Time delay relay 10 A 240 Vac 3
27 Triple pole Contactor 20A 240Vac 3
28 Batten type Lamp holder 240Vac 10 A 3
29 Start stop button 240Vac 10A 2
30 Indicating light (Bulb ) 240Vac 25W 3
31 Overload Relay 415V 20A 1
32 Three phase dahlander type
induction motor
5 hp 1
33 Single phase step down
transformer
24024Vac
2500VA
1
79 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
34 Single core PVC insulated
Cable
1mm 2 As required
35 Single core PVC insulated
Cable
25mm 2 As required
36 DIN rail 35 mm As required
37 PVC type Cable tray 50 mm x 50 mm As required
38 Cable ties 4 ldquo As required
39 Flexible wires 075 mm As required
40 PVC Connectors 5 A amp 20 A 240 V As required
41 Terminal block 20A 240Vac As required
Procedures
5 Identify each component according to specification and quantity required from the schematic
diagram attached
6 Test the functionality of each component by using multi-meter or power supply whichever
applicable
7 Wire component according to circuit diagram
8 Three motors operated in sequence by DOL starter operated by manual push button or time
delay relay
a One loop per-cycle
b Continuous operation in a loop
c optional circuit design to represent the same task
d Only one out of three motors to be operated at a time (quiz)
9 Test the functionality of completed project
80 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
BASIC DESIGN INDUSTRIAL MOTOR CONTROL (SEQUENCE CONTROL)
THREE PHASE INDUCTION MOTOR OPERATED IN SEQUENCE BY DIRECT ON LINE
STARTER
LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
81 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
82 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Lcd lamp indicator 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
11 Overload Relay 415V 20A 3
12 Three phase induction motor 5 hp 3
13 Single phase step down transformer 2500VA 1
14 Single core PVC insulated Cable 1mm 2 As required
15 Single core PVC insulated Cable 25mm 2 As required
16 DIN rail 35 mm As required
17 PVC type Cable tray 50 mm x 50 mm As required
18 Cable ties 4 ldquo As required
19 Flexible wires 1 mm Oslash As required
20 PVC Terminal block 10A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the schematic
diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a optional exercise
i Forward Reverse dahlander motor
4 Test the functionality of completed project
83 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
THREE PHASE DAHLANDER TYPE INDUCTION MOTOR OPERATED FORWARD AND
REVERSE OPERATION BY DIRECT ON LINE STARTER
84 ndash 99EASYTECH ENTERPRISE
LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
Introduction
If a motors windings are connected in the star configuration any two phases will be in series across
the supply and hence the line current will be smaller(by 577) than if the windings were connected in
the delta arrangement
Hence larger-type motors with heavy starting currents are first connected in star and then when the
starting currents fall in delta This of course means that all six of the ends of the windings must be
brought to terminations outside the casing (Fig 833)
EZTECH
EZTECH ELECTRICAL INSTALLATION GUIDE
The automatic version of this starter incorporates a timing relay which automatically changes the
connections from star to delta Figs 834 and 835 show the wiring and schematic diagrams for a star
delta starter
Objectives
1 Identify component and the specification
2 Design forward reverse star delta starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
2 ndash 99EASYTECH ENTERPRISE
REV -C
LEGENDMCCB Moulded Case Circuit BreakerTOR Thermal Over Load RelayFOW-C Mains Forward ContactorREV-C Mains Reverse ContactorDC Delta ContactorSC Star ContactorS-SW Mains Selector Switch
SC
V2
W2
U2
DC
V1
W1
U1
TOR
TOR
FOW-C
30A MCCB
TOR
MAIN CIRCUIT FORWARD REVERSE STAR DELTA
RYBN S
-SW
3 PHASEINDUCTION MOTOR
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Relay 10 A 240V 3
5 Triple pole Contactor
6 cw NO NC auxiliary contact
240Vac 20 A 4
7 Overload Relay 415 V 1
8 LED indicator 240vac 5 A 4
9 Start stop button 240Vac 5A 2
10 DIN rail 35 mm As required
11 Flexible wires 1 mm As required
12 Single core PVC insulated
wire
25 mm As required
13 Terminal block 20 A As required
14 Squirrel cage motor 5kW 1
15 5 pin plug and socket 415V 20A 1
16 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
3 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
a Manual star delta
b Manual Forward reverse star delta starter
c Automatic star delta starter
d Automatic Forward reverse star delta starter
4 Test the functionality of completed project
4 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
Objectives
1 Identify component and the specification
2 Design auto transformer starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
5 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Autotransformer starter is used to start a 3 phase induction motor that has a rating between 10 to 15 hp
6 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Autotransformer set 10Kw 415 V 50 Hz 1
5 Triple pole Contactor 240Vac 4
6 Batten type Lamp holder 240 Vac 105 A 4
7 Start stop button 240Vac 10A 4
8 Filament lamp (Bulb ) 240Vac 40W 4
9 DIN rail 35 mm As required
10 Flexible wires 1 mm As required
7 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
11 Single core PVC insulated
wire
25 mm As required
12 Terminal block 20 A As required
13 Squirrel cage motor 10kW 1
14 5 pin plug and socket 415V 20A 1
15 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a open transient autotransformer starter
b close transient autotransformer starter
c Forward reverse autotransformer starter
4 Test the functionality of completed project
8 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
Objectives
1 Identify component and the specification
2 Design rotor resistance starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
9 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Rotor Resistor set 10kW 1
5 Triple pole Contactor 240Vac 20A 4
6 Indicating light 240vac 5 A 4
7 Start stop push button 240Vac 5A 4
8 DIN rail 35 mm As required
9 Flexible wires 1 mm 2 As required
10 Single core PVC insulated wire 25 mm 2 As required
11 Terminal block 20 A As required
12 Slip Ring motor 10kW 1
13 5 pin round 3 phase socket 415V 20A 1
14 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
10 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
4 Test the functionality of completed project
a Dead circuit test b Life circuit test
5 Measure starting and running Amps
LESSON 16
TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
An installation in general will suffer damage
Damage usually occurs on the electric motor control as follows
1 Damage to the main circuit
2 Damage to the control circuit
The cause of the damage
i Overcurrent overload short circuit
ii Leakage current to ground
iii Equipment malfunction
iv The main control circuit
a Trip of main circuit protection devices fire
b Defect of motor terminal such as short circuit fire loose
v The control circuit is not functioning -
a contactor relay relay time overload relay does not work damaged burned
b Loose cable connection disconnected
Detecting and Repairing Damage
Examples of damage are as follows
i Motor does not work
ii Motor function and overload relay trips
iii Motor function but only partially functional control circuit
Methods of detecting damage
Among the known methods necessary to detect damage are as follows
1 Turn off the electricity at the main switch (main switch) in order to avoid any danger during the
work carried out to detect damage
2 Check all the protective gear that controls the motor control main circuit
11 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
3 Make sure the damage function control circuit
4 Check the control circuit according to the schematic circuit diagram of the motor control
5 Check the operation of the control circuit
Note
Use wiring that has been installed on the SYSTEM OF MOTOR CONTROL BOARD by Forward
Reverse control circuit for Star Delta to test and look for damage
SELF-ASSESSMENT QUESTIONS
1 (a) Explain what is meant by the term lsquoback emfrsquo in a motor
(b) Outline the basic differences between series shunt and compound wound dc motors
2 (a) With the aid of diagrams explain how the speed of series shunt and compound-wound motors
may be controlled
(b) A 440V dc shunt-wound motor has a field resistance of 200R and an armature resistance of 06 R
When its speed is 20 rev d second the current drawn from the supply is 122A Calculate its back
emf at this speed If the speed were decreased to 19 revssecond the field flux remaining unchanged
calculate the new back emf and the new armature current
3 A load of 64 kW at 240 V is supplied from the terminals of a shunt-wound dc generator The field
resistance is 180 A Calculate the armature current
4 (a) Explain with the aid of a diagram how a rotating magnetic field may be
(b) What is meant by lsquosynchronous speedrsquo
Calculate the synchronous obtained speed of a 12 pole motor if the supply frequency is 50Hz
5 (a) Explain the action of a synchronous motor
(b) What methods are available to start a synchronous motor Explain with diagrams
6 (a) Explain the action of a cage induction motor
(b) What is meant by the term lsquosliprsquo
Calculate the percentage slip of a six pole induction motor running at 162 revssecond from a 50 Hz
supply
7 Describe with sketches three different ways of starting a single-phase induction motor
12 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
8 Explain with the aid of a sketch the action of a three-phase DOL starter
What are dashpots used for How are remote start and stop buttons connected
9 A I0 kW 240V 50Hz single-phase cage rotor induction motor is 85efficient and has a PF of 068
lagging Calculate the motor current and the value of capacitor required to raise the PF to 093
lagging
10 Calculate the torque developed by an 18 kW four-pole induction motor run at 35 slip from a
50Hz supply
APPENDIX 1
13 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 11
14 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 111
Attachment Reference
httpswwwtlc-directcoukBook621htm
httpwwwstgovmyindexphpms
15 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Ring circuit
(floor area 100 m2)25 15 3032
A2 radial circuit
(floor area 75 m2)40 25 3032
A3 radial circuit
(floor area 50 m2)25 15 20
Air conditioner (15 tonne) 60 60 3032
Cooker 60 60 3032
Water heater 40 40 20
Objectives
1 Identify component and the specification
2 Wire component according to the schematic diagram
3 Test the functionality of the circuit
42 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board Perforated 1
2 Cut out fuse and neutral link 60A 240V 1each
3 kWh meter 240V 40A 1
4 Switched Socket outlet 13A 240Vac 4
5 Single pole two way switch cw switch
box
5A 240Vac 2
6 RCCB ELCB 63 A Tripping current 100mA
415 Vac
1
7 3 pin plug 240Vac 13A 4
8 Single pole MCB 20 A 2
9 Single pole MCB 6A 1
10 Single pole MCB 20A 2
11 DOL starter 240Vac 2
12 1 phase induction motor 2hp 240 Vac 1
13 Self tapping Wood screw As required
14 DIN rail Stainless steel allum35 mm As required
15 PVC pipe 20mm dia As required
16 End box 20 mm dia 4
17 Flexible wires 05 mm 2 As required
18 Connectors 5 A As required
Procedures
43 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
4 Test the functionality of completed project
LESSON 6 ndash WIRING SYSTEM OF 3 Oslash DISTRIBUTION BOARD
Introduction
44 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
45 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
46 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
47 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
48 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify each component and the specification
2 Wire component according to the schematic diagram given
3 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting Board 450 x 600 mm Perforated metal 1
2 5 pin round socket and plug 415V ac 32A 1
3 Cut out fuse 60 A 3
4 Neutral link 1
5 kWatt hour meter 415V 60A 1
6 ELCB RCCB 3P+N In=63A415 Vac I trip= 300mA 1
7 ELCB RCCB 3P+N In=63A415 Vac I trip= 30mA 1
8 Single pole MCB 6A 240 V 3
9 Single pole MCB 20A 240 V 3
10 DOL starter 20 A 240Vac 2
11 Socket outlet 15 A 240 Vac 1
12 Switched Socket outlet 13 A 240 Vac 3
13 Led indicating light 5A 240 Vac 3
14 Single pole 4 gang 1 way switch 5A 240 Vac 2
15 Single pole 2 way switch 5A 240 Vac 2
16 1 phase induction motor 1 kW 240Vac 1
17 Metal trunking 30 mm x30 mm As required
18 Self tapping Wood screw 4 mm x 20 mm As required
19 DIN rail 25 mm x 1mm
20 GI steel rigid conduit 20mm As required
21 Flexible conduit 20mm As required
22 End box 20 mm 4
23 Flexible wires 05 mm 2 As required
24 Single core PVC insulated wire 15 mm 2 As required
25 Single core PVC insulated wires 25 mm 2 As required
26 Terminal block 10 A As required
Procedures
49 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify each components and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
4 Test the functionality of completed project
1 dead circuit test
2 life circuit
Note Proper earthing should be made
50 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 7 ndash WIRING SYSTEM OF THREE PHASE LIGHTING AND POWER CIRCUIT
51 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
52 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify component and the specification
2 Wire component according to the schematic diagram
3 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting bay Board Perforated metal 180 cm x 180 cm 1
2 k Watt hour meter 415V 60A 1
3 MCCB 415V 60A
4 ELCB RCCB In=60A415 Vac I trip=30mA 1
5 5 pin round Socket and
plug
415Vac 32A 4
6 Single pole MCB 6A 1
7 Triple pole MCB 20A 2
8 Triple pole Main switch 60A 1
9 DOL starter 240Vac 2
10 3 phase induction motor 2hp 415 Vac 1
11 1 phase induction motor 1
12 Metal trunking 30 mm x30 mm As required
13 Self tapping Wood screw 4 mm x 20 mm As required
14 DIN rail 25 mm x 1mm
15 GI steel rigid conduit 20mm As required
16 Flexible conduit 20mm As required
17 End box 20 mm 4
18 Flexible wires 05 mm As required
19 Connectors 10 A As required
Procedures
1 Identify each components and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
4 Test the functionality of completed project
1 dead circuit 2 life circuit test
5 Record the current drawn by the load as connected in star and delta
Note Proper earthing should be made
53 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 8 INSPECTION AND TESTING OF ELECTRICAL INSTALLATION
On completion of a wiring installation a number of tests on the installation have to be conducted to
ascertain that the wiring circuits and connected appliances are safe for use Prior to carrying out the
tests an inspection has to be done The results of the inspectionsupervision and test have to be
presented in Form G (as in Appendix IV) and Form H (as in Appendix V)
To have the test certification as in Form H the following tests shall be conducted
i Continuity Test
ii Insulation Resistance Test
iii Polarity Test
iv Earth Electrode Resistance test and
v Residual Current Device Test
1 Continuity Test
There are 3 main types of continuity tests for the final circuits-
i Protection Conductor Continuity Test
ii Final Ring Circuit Conductor Continuity Test
iii Live and Neutral Conductor Continuity Test
a) Protection Conductor Continuity Test
bull To ascertain that all protection conductors are connected in the correct and effective manner
bull Test equipment ndash Multimeter (Ohm range) or Ohm meter
54 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
bull Test Method
1 1048766 Ensure that the main switch RCD and MCB are open circuited (switched off) and all loads
are disconnected
2 1048766 Connected the test leads as in the Figure 81 The meter reading shall be less than 1 Ω
55 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Final Ring Circuit Conductor Continuity Test
bull To ensure that all conductors around the ring circuit have continuity
bull Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
bull Test Method
1 1048766 Disconnect both the supply source live conductors from the MCB the neutral conductor
from the neutral terminals and the earth conductor from the earth terminal in the distribution
fuse box
2 1048766 Connect the test leads as in the Figure 82 (EE)
3 1048766 Repeat the procedure for (L-L) and (N-N)
4 1048766 The meter reading value shall be less than 1 ohm
56 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Live and Neutral Conductor Continuity Test
a To ensure that each conductor in the circuit has continuity
b Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
2 Test Method
1 1048766 Switch off the Main switch RCD and MCB
2 1048766 Disconnect all loads
3 1048766 Switch on all switches in the circuit
4 1048766 Disconnect the fusesfinal circuit breakers and close the circuit
5 1048766 Carry out the test as shown in Figure 83
6 1048766 The meter reading value shall be less than 1Ω
57 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
58 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
CONTINUITY TEST
Insulation Resistance Test
i Ensure that there is no leakage current between phase conductors phase and neutral conductors and
phase conductor and earth
ii Test the strength of the cable insulation
iii Test Equipment ndash Insulation Resistance Tester operating voltage is 250VDC or 500VDC
iv Test Method
1 1048766 Switch off main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
59 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
4 1048766 Carry out test as in the Table below
5 1048766 Meter reading value shall be less than 1 Megaohm
60 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
61 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Insulation resitance test
62 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
INSULATION RESISTANCE TEST BETWEEN CONDUCTORS AND OPPOSITE POLARITY
Polarity Testi Ensure that each fuse or single pole control and protection device is connected only in the phase
conductor
ii Intermediate contact of Edison screw lamp holder is connected to the phase conductor
iii Ensure that phase neutral and earth conductors at socket outlets are connected at the correct
terminals
iv Test Equipment ndash Multimeter (Ohm range) or Ohm meter
v Test Method
1 1048766 Switch off Main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in Figure 85
63 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
5 1048766 Test switches and single phase control devices at the phase conductors
6 1048766 Test socket outlet connection sources
7 1048766 Test Edison screw lamp holder connections
8 1048766 Meter reading value shall be less than 1 Ω
64 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Polarity test
65 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Earth Electrode Resistance Testi To test the earth electrode resistance
ii To ascertain the suitability of the location of the electrode
iii To ensure that the electrode is not buried within the resistance area of another electrode
iv Test equipment ndash Earth Resistance Tester
v Test method -
1 1048766 Terminal rsquoErsquo is connected to the electrode to be tested (green conductor)
2 1048766 Terminal lsquoPrsquo is connected to the potential spike (yellow conductor) at a distance of 10
meters from the earth electrode
3 1048766 Terminal lsquoCrsquo is connected to the current spike (red conductor) at a distance of 20 meters
from the earth electrode
Earth Electrode Resistance Measurement Method (Figure 86)
This test must be repeated at least three times to ensure that the reading is not affected by interacting
earthing regions
i Record the first reading (Z1) Example Z1 = 10 Ω
ii Move the voltage spike to a distance of 6 meters from the original position Record the second
reading (Z2 ) Example Z2 = 10 Ω
iii Move the voltage spike to a distance of 6 meters from the original position Record the third
reading (Z3) Example Z3 = 10 Ω
66 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Residual Current Device Testi Ensure that the residual current device (RCD) trips within the set time on the occurrence of current
leakage to earth
ii Test Equipment ndash RCD Tester RCCB Tester
iii Test Method 1
1 1048766 Use the Trip Test Button
2 1048766 Press the trip button found on the RCD to determine if it trips or otherwise This test would
not be able to determine the sensitivity of the RCD nor the time taken for it to trip
iv Test Method 2
i 1048766 Use a RCD Tester
ii This equipment is equipped with a 13A plug which can be connected to a 13A socket outlet
Select the RCD sensitivity to be the same as the sensitivity of the RCD to be tested to
determine if the RCD can trip The time to trip shall not exceed 40 mS
iii 1048766 Test method ndash
a) Position the selection switch in accordance with the sensitivity of the RCD used
Example 100 mA 01 A
b) Position the operations switch to lsquoNo Triprsquo (frac12 Rated mA = 50) connect the 3 pin plug to
the 13A socket outlet
67 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
c) Switch on the 13A socket outlet ndash ensure that the P-N and P-E lights light up
This shows that the polarity is correct (Note if both the lights as above do not light up the test cannot
be continued)
d) Press the test button ndash the reading shows less than 200 mS and simultaneously the lsquotestrsquo light lights
up and the P-N and P-E lights do not light up At that instant the RCD will not trip
e) Move the selection switch to 180o (+ve wave) ndash repeat steps (d) and (e) Move the operations
switch to lsquoTriprsquo (Rated mA = 100)
g) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200mS
h) Move the selection switch to 0o (-ve wave)
i) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
j) The above test is repeated until a near correct reading is obtained
k) Record the test results
l) Change the operations switch to lsquoFast Triprsquo and press the test button ndash RCD will trip within a
time not exceeding 40 millisecond
m) Repeat a number of times at 0o or 180o
On completion of a wiring installation a number of tests on the installation have to be conducted to
ascertain that the wiring circuits and connected appliances are safe for use Prior to carrying out the
tests an inspection has to be done the following tests shall be conducted
i Continuity Test
ii Insulation Resistance Test
iii Polarity Test
iv Earth Electrode Resistance test and
v Residual Current Device Test
821 Continuity Test
There are 3 main types of continuity tests for the final circuits-
i Protection Conductor Continuity Test
ii Final Ring Circuit Conductor Continuity Test
68 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
iii Live and Neutral Conductor Continuity Test
a) Protection Conductor Continuity Test
bull To ascertain that all protection conductors are connected in the correct and effective manner
bull Test equipment ndash Multimeter (Ohm range) or Ohm meter
bull Test Method
1 1048766 Ensure that the main switch RCD and MCB are open circuited (switched off) and all loads are
disconnected
2 1048766 Connected the test leads as in the Figure 81
3 1048766 The meter reading shall be less than 1 Ω
Final Ring Circuit Conductor Continuity Test
bull To ensure that all conductors around the ring circuit have continuity
bull Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
bull Test Method
1 1048766 Disconnect both the supply source live conductors from the MCB the neutral conductor
from the neutral terminals and the earth conductor from the earth terminal in the distribution
fuse box
2 1048766 Connect the test leads as in the Figure 82 (EE)
3 1048766 Repeat the procedure for (L-L) and (N-N)
4 1048766 The meter reading value shall be less than 1 ohm Figure 82 - Final Ring Circuit Conductor
Continuity Test Ohm Meter
Disconnect both the supply source cables from mcbfuse
Take readings at earth conductors of both sources and note resistance readings
Live and Neutral Conductor Continuity Test
1 To ensure that each conductor in the circuit has continuity
2 Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
3 Test Method
1 1048766 Switch off the Main switch RCD and MCB
2 1048766 Disconnect all loads
3 1048766 Switch on all switches in the circuit
4 1048766 Disconnect the fusesfinal circuit breakers and close the circuit
5 1048766 Carry out the test as shown in Figure 83
6 1048766 The meter reading value shall be less than 1 ohm Figure 83 - Live and Neutral
Conductor Continuity Test Ohm Meter
Insulation Resistance Test
69 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
i Ensure that there is no leakage current between phase conductors phase and neutral conductors and
phase conductor and earth
ii Test the strength of the cable insulation
iii Test Equipment ndash Insulation Resistance Tester Operating voltage is 250VDC or 500VDC
iv Test Method
1 1048766 Switch off main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in the Table below
5 1048766 Meter reading value shall be less than 1 Megaohm
Polarity Test
i Ensure that each fuse or single pole control and protection device is connected only in the phase
conductor
ii Intermediate contact of Edison screw lamp holder is connected to the phase conductor
iii Ensure that phase neutral and earth conductors at socket outlets are connected at the correct
terminals
iv Test Equipment ndash Multimeter (Ohm range) or Ohm meter
v Test Method
1 1048766 Switch off Main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in Figure 85
5 1048766 Test switches and single phase control devices at the phase conductors
6 1048766 Test socket outlet connection sources
7 1048766 Test Edison screw lamp holder connections
8 1048766 Meter reading value shall be less than 1 Ω
Earth Electrode Resistance Test
i To test the earth electrode resistance
70 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
ii To ascertain the suitability of the location of the electrode
iii To ensure that the electrode is not buried within the resistance area of another electrode
iv Test equipment ndash Earth Resistance Tester
v Test method -
1 1048766 Terminal rsquoErsquo is connected to the electrode to be tested (green conductor)
2 1048766 Terminal lsquoPrsquo is connected to the potential spike (yellow conductor) at a distance of 10
meters from the earth electrode
3 1048766 Terminal lsquoCrsquo is connected to the current spike (red conductor) at a distance of 20 meters
from the earth electrode E P C Electrode 10 meter 10 meter
Figure 86 ndash Earth Electrode Resistance Measurement Test Equipment
Earth Electrode Resistance Measurement Method (Figure 86)
This test must be repeated at least three times to ensure that the reading is not affected by interacting
earthing regions
i Record the first reading (Z1) Example Z1 = 10 Ω
ii Move the voltage spike to a distance of 6 meters from the original position Record the second
reading (Z2) Example Z2 = 10 Ω
iii Move the voltage spike to a distance of 6 meters from the original position Record the third
reading (Z3)
Example Z3 = 10 Ω
Residual Current Device Test
71 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
i Ensure that the residual current device (RCD) trips within the set time on the occurrence of current
leakage to earth
ii Test Equipment ndash RCD Tester RCCB Tester
iii Test Method 1
1 1048766 Use the Trip Test Button
2 1048766 Press the trip button found on the RCD to determine if it trips or otherwise This test would
not be able to determine the sensitivity of the RCD nor the time taken for it to trip
iv Test Method 2
1048766 Use a RCD Tester
This equipment is equipped with a 13A plug which can be connected to a 13A socket outlet Select the
RCD sensitivity to be the same as the sensitivity of the RCD to be tested to determine if the RCD can
trip The time to trip shall not exceed 40 mS
1048766 Test method ndash
a) Position the selection switch in accordance with the sensitivity of the RCD used
Example 100 mA 01 A
b) Position the operations switch to lsquoNo Triprsquo (frac12 Rated mA = 50) connect the 3 pin plug to
the 13A socket outlet
c) Switch on the 13A socket outlet ndash ensure that the P-N and P-E lights light up This shows that
the polarity is correct (Note if both the lights as above do not light up the test cannot be
continued)
d) Press the test button ndash the reading shows less than 200 millisecond and simultaneously the
lsquotestrsquo light lights up and the P-N and P-E lights do not light up At that instant the RCD will
not trip
e) Move the selection switch to 180o (+ve wave) ndash repeat steps (d) and (e) = 100)
f) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
g) Move the selection switch to 0o (-ve wave)
h) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
i) The above test is repeated until a near correct reading is obtained
j) Record the test results
k) Change the operations switch to lsquoFast Triprsquo and press the test button ndash RCD will trip within a
time not exceeding 40 mS
l) Repeat a number of times at 0o or 180o
72 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 9 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (DC)
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
73 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Start stop button 240Vac 5A 2
9 Filament lamp (Bulb ) 240Vac 40W 3
10 Overload Relay 415V 20A 3
11 Three phase induction motor 5 hp 3
12 Single phase step down transformer 2500VA 1
13 Single core PVC insulated Cable 1mm 2 As required
14 Single core PVC insulated Cable 25mm 2 As required
15 DIN rail 35 mm As required
16 PVC type Cable tray 50 mm x 50 mm As required
17 Cable ties 4 ldquo As required
18 Flexible wires 05 mm As required
19 PVC Connectors 5 A amp 20 A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the schematic
diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a optional exercise
i Simple DOL starter
ii Forward reverse DOL starter
iii Forward Reverse Dahlander motor
iv Three motors operated in sequence by DOL starter operated by manual push
button or time delay relay
74 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
a One loop per-cycle
b Continuous operation in a loop
c optional circuit design to represent the same task
v Only one out of three motors to be operated at a time (quiz)
4 Test the functionality of completed project
LESSON 10 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (AC)
75 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 1
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Lamp point 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
76 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
11 Overload Relay 415V 20A 3
12 Three phase induction
motor
5 hp 3
13 Single core PVC insulated
Cable
1mm 2 As required
14 Single core PVC insulated
Cable
25mm 2 As required
15 DIN rail 35 mm As required
16 PVC type Cable tray 50 mm x 50 mm As required
17 Cable ties 4 ldquo As required
18 Flexible wires 05 mm As required
19 PVC Connectors 5 A amp 20 A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the
schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram optional exercise
4 Simple DOL starter
5 Forward reverse DOL starter
6 Test the functionality of completed project
77 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 1
78 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
cm
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Indicating light 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
11 Overload Relay 415V 20A 3
12 Three phase induction motor 5 hp 3
13 Single phase step down
transformer
2500VA 1
14 Single core PVC insulated
Cable
1mm 2 As required
15 Single core PVC insulated
Cable
25mm 2 As required
16 DIN rail 35 mm As required
17 PVC type Cable tray 50 mm x 50 mm As required
18 Cable ties 4 ldquo As required
19 Flexible wires 05 mm As required
20 PVC Connectors 5 A amp 20 A 240 V As required
21 Single pole MCB 6A 240 V 1
22 Single pole MCB 2A 240 V 1
23 Triple pole MCB 20A 415 V 1
24 Mounting board 30 cm x 40 cm x 3
cm
1
25 Relay cw 11 pin socket 10 A 240 Vac 2
26 Time delay relay 10 A 240 Vac 3
27 Triple pole Contactor 20A 240Vac 3
28 Batten type Lamp holder 240Vac 10 A 3
29 Start stop button 240Vac 10A 2
30 Indicating light (Bulb ) 240Vac 25W 3
31 Overload Relay 415V 20A 1
32 Three phase dahlander type
induction motor
5 hp 1
33 Single phase step down
transformer
24024Vac
2500VA
1
79 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
34 Single core PVC insulated
Cable
1mm 2 As required
35 Single core PVC insulated
Cable
25mm 2 As required
36 DIN rail 35 mm As required
37 PVC type Cable tray 50 mm x 50 mm As required
38 Cable ties 4 ldquo As required
39 Flexible wires 075 mm As required
40 PVC Connectors 5 A amp 20 A 240 V As required
41 Terminal block 20A 240Vac As required
Procedures
5 Identify each component according to specification and quantity required from the schematic
diagram attached
6 Test the functionality of each component by using multi-meter or power supply whichever
applicable
7 Wire component according to circuit diagram
8 Three motors operated in sequence by DOL starter operated by manual push button or time
delay relay
a One loop per-cycle
b Continuous operation in a loop
c optional circuit design to represent the same task
d Only one out of three motors to be operated at a time (quiz)
9 Test the functionality of completed project
80 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
BASIC DESIGN INDUSTRIAL MOTOR CONTROL (SEQUENCE CONTROL)
THREE PHASE INDUCTION MOTOR OPERATED IN SEQUENCE BY DIRECT ON LINE
STARTER
LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
81 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
82 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Lcd lamp indicator 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
11 Overload Relay 415V 20A 3
12 Three phase induction motor 5 hp 3
13 Single phase step down transformer 2500VA 1
14 Single core PVC insulated Cable 1mm 2 As required
15 Single core PVC insulated Cable 25mm 2 As required
16 DIN rail 35 mm As required
17 PVC type Cable tray 50 mm x 50 mm As required
18 Cable ties 4 ldquo As required
19 Flexible wires 1 mm Oslash As required
20 PVC Terminal block 10A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the schematic
diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a optional exercise
i Forward Reverse dahlander motor
4 Test the functionality of completed project
83 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
THREE PHASE DAHLANDER TYPE INDUCTION MOTOR OPERATED FORWARD AND
REVERSE OPERATION BY DIRECT ON LINE STARTER
84 ndash 99EASYTECH ENTERPRISE
LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
Introduction
If a motors windings are connected in the star configuration any two phases will be in series across
the supply and hence the line current will be smaller(by 577) than if the windings were connected in
the delta arrangement
Hence larger-type motors with heavy starting currents are first connected in star and then when the
starting currents fall in delta This of course means that all six of the ends of the windings must be
brought to terminations outside the casing (Fig 833)
EZTECH
EZTECH ELECTRICAL INSTALLATION GUIDE
The automatic version of this starter incorporates a timing relay which automatically changes the
connections from star to delta Figs 834 and 835 show the wiring and schematic diagrams for a star
delta starter
Objectives
1 Identify component and the specification
2 Design forward reverse star delta starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
2 ndash 99EASYTECH ENTERPRISE
REV -C
LEGENDMCCB Moulded Case Circuit BreakerTOR Thermal Over Load RelayFOW-C Mains Forward ContactorREV-C Mains Reverse ContactorDC Delta ContactorSC Star ContactorS-SW Mains Selector Switch
SC
V2
W2
U2
DC
V1
W1
U1
TOR
TOR
FOW-C
30A MCCB
TOR
MAIN CIRCUIT FORWARD REVERSE STAR DELTA
RYBN S
-SW
3 PHASEINDUCTION MOTOR
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Relay 10 A 240V 3
5 Triple pole Contactor
6 cw NO NC auxiliary contact
240Vac 20 A 4
7 Overload Relay 415 V 1
8 LED indicator 240vac 5 A 4
9 Start stop button 240Vac 5A 2
10 DIN rail 35 mm As required
11 Flexible wires 1 mm As required
12 Single core PVC insulated
wire
25 mm As required
13 Terminal block 20 A As required
14 Squirrel cage motor 5kW 1
15 5 pin plug and socket 415V 20A 1
16 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
3 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
a Manual star delta
b Manual Forward reverse star delta starter
c Automatic star delta starter
d Automatic Forward reverse star delta starter
4 Test the functionality of completed project
4 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
Objectives
1 Identify component and the specification
2 Design auto transformer starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
5 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Autotransformer starter is used to start a 3 phase induction motor that has a rating between 10 to 15 hp
6 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Autotransformer set 10Kw 415 V 50 Hz 1
5 Triple pole Contactor 240Vac 4
6 Batten type Lamp holder 240 Vac 105 A 4
7 Start stop button 240Vac 10A 4
8 Filament lamp (Bulb ) 240Vac 40W 4
9 DIN rail 35 mm As required
10 Flexible wires 1 mm As required
7 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
11 Single core PVC insulated
wire
25 mm As required
12 Terminal block 20 A As required
13 Squirrel cage motor 10kW 1
14 5 pin plug and socket 415V 20A 1
15 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a open transient autotransformer starter
b close transient autotransformer starter
c Forward reverse autotransformer starter
4 Test the functionality of completed project
8 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
Objectives
1 Identify component and the specification
2 Design rotor resistance starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
9 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Rotor Resistor set 10kW 1
5 Triple pole Contactor 240Vac 20A 4
6 Indicating light 240vac 5 A 4
7 Start stop push button 240Vac 5A 4
8 DIN rail 35 mm As required
9 Flexible wires 1 mm 2 As required
10 Single core PVC insulated wire 25 mm 2 As required
11 Terminal block 20 A As required
12 Slip Ring motor 10kW 1
13 5 pin round 3 phase socket 415V 20A 1
14 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
10 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
4 Test the functionality of completed project
a Dead circuit test b Life circuit test
5 Measure starting and running Amps
LESSON 16
TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
An installation in general will suffer damage
Damage usually occurs on the electric motor control as follows
1 Damage to the main circuit
2 Damage to the control circuit
The cause of the damage
i Overcurrent overload short circuit
ii Leakage current to ground
iii Equipment malfunction
iv The main control circuit
a Trip of main circuit protection devices fire
b Defect of motor terminal such as short circuit fire loose
v The control circuit is not functioning -
a contactor relay relay time overload relay does not work damaged burned
b Loose cable connection disconnected
Detecting and Repairing Damage
Examples of damage are as follows
i Motor does not work
ii Motor function and overload relay trips
iii Motor function but only partially functional control circuit
Methods of detecting damage
Among the known methods necessary to detect damage are as follows
1 Turn off the electricity at the main switch (main switch) in order to avoid any danger during the
work carried out to detect damage
2 Check all the protective gear that controls the motor control main circuit
11 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
3 Make sure the damage function control circuit
4 Check the control circuit according to the schematic circuit diagram of the motor control
5 Check the operation of the control circuit
Note
Use wiring that has been installed on the SYSTEM OF MOTOR CONTROL BOARD by Forward
Reverse control circuit for Star Delta to test and look for damage
SELF-ASSESSMENT QUESTIONS
1 (a) Explain what is meant by the term lsquoback emfrsquo in a motor
(b) Outline the basic differences between series shunt and compound wound dc motors
2 (a) With the aid of diagrams explain how the speed of series shunt and compound-wound motors
may be controlled
(b) A 440V dc shunt-wound motor has a field resistance of 200R and an armature resistance of 06 R
When its speed is 20 rev d second the current drawn from the supply is 122A Calculate its back
emf at this speed If the speed were decreased to 19 revssecond the field flux remaining unchanged
calculate the new back emf and the new armature current
3 A load of 64 kW at 240 V is supplied from the terminals of a shunt-wound dc generator The field
resistance is 180 A Calculate the armature current
4 (a) Explain with the aid of a diagram how a rotating magnetic field may be
(b) What is meant by lsquosynchronous speedrsquo
Calculate the synchronous obtained speed of a 12 pole motor if the supply frequency is 50Hz
5 (a) Explain the action of a synchronous motor
(b) What methods are available to start a synchronous motor Explain with diagrams
6 (a) Explain the action of a cage induction motor
(b) What is meant by the term lsquosliprsquo
Calculate the percentage slip of a six pole induction motor running at 162 revssecond from a 50 Hz
supply
7 Describe with sketches three different ways of starting a single-phase induction motor
12 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
8 Explain with the aid of a sketch the action of a three-phase DOL starter
What are dashpots used for How are remote start and stop buttons connected
9 A I0 kW 240V 50Hz single-phase cage rotor induction motor is 85efficient and has a PF of 068
lagging Calculate the motor current and the value of capacitor required to raise the PF to 093
lagging
10 Calculate the torque developed by an 18 kW four-pole induction motor run at 35 slip from a
50Hz supply
APPENDIX 1
13 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 11
14 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 111
Attachment Reference
httpswwwtlc-directcoukBook621htm
httpwwwstgovmyindexphpms
15 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board Perforated 1
2 Cut out fuse and neutral link 60A 240V 1each
3 kWh meter 240V 40A 1
4 Switched Socket outlet 13A 240Vac 4
5 Single pole two way switch cw switch
box
5A 240Vac 2
6 RCCB ELCB 63 A Tripping current 100mA
415 Vac
1
7 3 pin plug 240Vac 13A 4
8 Single pole MCB 20 A 2
9 Single pole MCB 6A 1
10 Single pole MCB 20A 2
11 DOL starter 240Vac 2
12 1 phase induction motor 2hp 240 Vac 1
13 Self tapping Wood screw As required
14 DIN rail Stainless steel allum35 mm As required
15 PVC pipe 20mm dia As required
16 End box 20 mm dia 4
17 Flexible wires 05 mm 2 As required
18 Connectors 5 A As required
Procedures
43 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
4 Test the functionality of completed project
LESSON 6 ndash WIRING SYSTEM OF 3 Oslash DISTRIBUTION BOARD
Introduction
44 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
45 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
46 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
47 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
48 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify each component and the specification
2 Wire component according to the schematic diagram given
3 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting Board 450 x 600 mm Perforated metal 1
2 5 pin round socket and plug 415V ac 32A 1
3 Cut out fuse 60 A 3
4 Neutral link 1
5 kWatt hour meter 415V 60A 1
6 ELCB RCCB 3P+N In=63A415 Vac I trip= 300mA 1
7 ELCB RCCB 3P+N In=63A415 Vac I trip= 30mA 1
8 Single pole MCB 6A 240 V 3
9 Single pole MCB 20A 240 V 3
10 DOL starter 20 A 240Vac 2
11 Socket outlet 15 A 240 Vac 1
12 Switched Socket outlet 13 A 240 Vac 3
13 Led indicating light 5A 240 Vac 3
14 Single pole 4 gang 1 way switch 5A 240 Vac 2
15 Single pole 2 way switch 5A 240 Vac 2
16 1 phase induction motor 1 kW 240Vac 1
17 Metal trunking 30 mm x30 mm As required
18 Self tapping Wood screw 4 mm x 20 mm As required
19 DIN rail 25 mm x 1mm
20 GI steel rigid conduit 20mm As required
21 Flexible conduit 20mm As required
22 End box 20 mm 4
23 Flexible wires 05 mm 2 As required
24 Single core PVC insulated wire 15 mm 2 As required
25 Single core PVC insulated wires 25 mm 2 As required
26 Terminal block 10 A As required
Procedures
49 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify each components and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
4 Test the functionality of completed project
1 dead circuit test
2 life circuit
Note Proper earthing should be made
50 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 7 ndash WIRING SYSTEM OF THREE PHASE LIGHTING AND POWER CIRCUIT
51 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
52 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify component and the specification
2 Wire component according to the schematic diagram
3 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting bay Board Perforated metal 180 cm x 180 cm 1
2 k Watt hour meter 415V 60A 1
3 MCCB 415V 60A
4 ELCB RCCB In=60A415 Vac I trip=30mA 1
5 5 pin round Socket and
plug
415Vac 32A 4
6 Single pole MCB 6A 1
7 Triple pole MCB 20A 2
8 Triple pole Main switch 60A 1
9 DOL starter 240Vac 2
10 3 phase induction motor 2hp 415 Vac 1
11 1 phase induction motor 1
12 Metal trunking 30 mm x30 mm As required
13 Self tapping Wood screw 4 mm x 20 mm As required
14 DIN rail 25 mm x 1mm
15 GI steel rigid conduit 20mm As required
16 Flexible conduit 20mm As required
17 End box 20 mm 4
18 Flexible wires 05 mm As required
19 Connectors 10 A As required
Procedures
1 Identify each components and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
4 Test the functionality of completed project
1 dead circuit 2 life circuit test
5 Record the current drawn by the load as connected in star and delta
Note Proper earthing should be made
53 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 8 INSPECTION AND TESTING OF ELECTRICAL INSTALLATION
On completion of a wiring installation a number of tests on the installation have to be conducted to
ascertain that the wiring circuits and connected appliances are safe for use Prior to carrying out the
tests an inspection has to be done The results of the inspectionsupervision and test have to be
presented in Form G (as in Appendix IV) and Form H (as in Appendix V)
To have the test certification as in Form H the following tests shall be conducted
i Continuity Test
ii Insulation Resistance Test
iii Polarity Test
iv Earth Electrode Resistance test and
v Residual Current Device Test
1 Continuity Test
There are 3 main types of continuity tests for the final circuits-
i Protection Conductor Continuity Test
ii Final Ring Circuit Conductor Continuity Test
iii Live and Neutral Conductor Continuity Test
a) Protection Conductor Continuity Test
bull To ascertain that all protection conductors are connected in the correct and effective manner
bull Test equipment ndash Multimeter (Ohm range) or Ohm meter
54 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
bull Test Method
1 1048766 Ensure that the main switch RCD and MCB are open circuited (switched off) and all loads
are disconnected
2 1048766 Connected the test leads as in the Figure 81 The meter reading shall be less than 1 Ω
55 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Final Ring Circuit Conductor Continuity Test
bull To ensure that all conductors around the ring circuit have continuity
bull Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
bull Test Method
1 1048766 Disconnect both the supply source live conductors from the MCB the neutral conductor
from the neutral terminals and the earth conductor from the earth terminal in the distribution
fuse box
2 1048766 Connect the test leads as in the Figure 82 (EE)
3 1048766 Repeat the procedure for (L-L) and (N-N)
4 1048766 The meter reading value shall be less than 1 ohm
56 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Live and Neutral Conductor Continuity Test
a To ensure that each conductor in the circuit has continuity
b Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
2 Test Method
1 1048766 Switch off the Main switch RCD and MCB
2 1048766 Disconnect all loads
3 1048766 Switch on all switches in the circuit
4 1048766 Disconnect the fusesfinal circuit breakers and close the circuit
5 1048766 Carry out the test as shown in Figure 83
6 1048766 The meter reading value shall be less than 1Ω
57 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
58 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
CONTINUITY TEST
Insulation Resistance Test
i Ensure that there is no leakage current between phase conductors phase and neutral conductors and
phase conductor and earth
ii Test the strength of the cable insulation
iii Test Equipment ndash Insulation Resistance Tester operating voltage is 250VDC or 500VDC
iv Test Method
1 1048766 Switch off main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
59 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
4 1048766 Carry out test as in the Table below
5 1048766 Meter reading value shall be less than 1 Megaohm
60 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
61 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Insulation resitance test
62 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
INSULATION RESISTANCE TEST BETWEEN CONDUCTORS AND OPPOSITE POLARITY
Polarity Testi Ensure that each fuse or single pole control and protection device is connected only in the phase
conductor
ii Intermediate contact of Edison screw lamp holder is connected to the phase conductor
iii Ensure that phase neutral and earth conductors at socket outlets are connected at the correct
terminals
iv Test Equipment ndash Multimeter (Ohm range) or Ohm meter
v Test Method
1 1048766 Switch off Main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in Figure 85
63 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
5 1048766 Test switches and single phase control devices at the phase conductors
6 1048766 Test socket outlet connection sources
7 1048766 Test Edison screw lamp holder connections
8 1048766 Meter reading value shall be less than 1 Ω
64 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Polarity test
65 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Earth Electrode Resistance Testi To test the earth electrode resistance
ii To ascertain the suitability of the location of the electrode
iii To ensure that the electrode is not buried within the resistance area of another electrode
iv Test equipment ndash Earth Resistance Tester
v Test method -
1 1048766 Terminal rsquoErsquo is connected to the electrode to be tested (green conductor)
2 1048766 Terminal lsquoPrsquo is connected to the potential spike (yellow conductor) at a distance of 10
meters from the earth electrode
3 1048766 Terminal lsquoCrsquo is connected to the current spike (red conductor) at a distance of 20 meters
from the earth electrode
Earth Electrode Resistance Measurement Method (Figure 86)
This test must be repeated at least three times to ensure that the reading is not affected by interacting
earthing regions
i Record the first reading (Z1) Example Z1 = 10 Ω
ii Move the voltage spike to a distance of 6 meters from the original position Record the second
reading (Z2 ) Example Z2 = 10 Ω
iii Move the voltage spike to a distance of 6 meters from the original position Record the third
reading (Z3) Example Z3 = 10 Ω
66 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Residual Current Device Testi Ensure that the residual current device (RCD) trips within the set time on the occurrence of current
leakage to earth
ii Test Equipment ndash RCD Tester RCCB Tester
iii Test Method 1
1 1048766 Use the Trip Test Button
2 1048766 Press the trip button found on the RCD to determine if it trips or otherwise This test would
not be able to determine the sensitivity of the RCD nor the time taken for it to trip
iv Test Method 2
i 1048766 Use a RCD Tester
ii This equipment is equipped with a 13A plug which can be connected to a 13A socket outlet
Select the RCD sensitivity to be the same as the sensitivity of the RCD to be tested to
determine if the RCD can trip The time to trip shall not exceed 40 mS
iii 1048766 Test method ndash
a) Position the selection switch in accordance with the sensitivity of the RCD used
Example 100 mA 01 A
b) Position the operations switch to lsquoNo Triprsquo (frac12 Rated mA = 50) connect the 3 pin plug to
the 13A socket outlet
67 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
c) Switch on the 13A socket outlet ndash ensure that the P-N and P-E lights light up
This shows that the polarity is correct (Note if both the lights as above do not light up the test cannot
be continued)
d) Press the test button ndash the reading shows less than 200 mS and simultaneously the lsquotestrsquo light lights
up and the P-N and P-E lights do not light up At that instant the RCD will not trip
e) Move the selection switch to 180o (+ve wave) ndash repeat steps (d) and (e) Move the operations
switch to lsquoTriprsquo (Rated mA = 100)
g) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200mS
h) Move the selection switch to 0o (-ve wave)
i) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
j) The above test is repeated until a near correct reading is obtained
k) Record the test results
l) Change the operations switch to lsquoFast Triprsquo and press the test button ndash RCD will trip within a
time not exceeding 40 millisecond
m) Repeat a number of times at 0o or 180o
On completion of a wiring installation a number of tests on the installation have to be conducted to
ascertain that the wiring circuits and connected appliances are safe for use Prior to carrying out the
tests an inspection has to be done the following tests shall be conducted
i Continuity Test
ii Insulation Resistance Test
iii Polarity Test
iv Earth Electrode Resistance test and
v Residual Current Device Test
821 Continuity Test
There are 3 main types of continuity tests for the final circuits-
i Protection Conductor Continuity Test
ii Final Ring Circuit Conductor Continuity Test
68 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
iii Live and Neutral Conductor Continuity Test
a) Protection Conductor Continuity Test
bull To ascertain that all protection conductors are connected in the correct and effective manner
bull Test equipment ndash Multimeter (Ohm range) or Ohm meter
bull Test Method
1 1048766 Ensure that the main switch RCD and MCB are open circuited (switched off) and all loads are
disconnected
2 1048766 Connected the test leads as in the Figure 81
3 1048766 The meter reading shall be less than 1 Ω
Final Ring Circuit Conductor Continuity Test
bull To ensure that all conductors around the ring circuit have continuity
bull Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
bull Test Method
1 1048766 Disconnect both the supply source live conductors from the MCB the neutral conductor
from the neutral terminals and the earth conductor from the earth terminal in the distribution
fuse box
2 1048766 Connect the test leads as in the Figure 82 (EE)
3 1048766 Repeat the procedure for (L-L) and (N-N)
4 1048766 The meter reading value shall be less than 1 ohm Figure 82 - Final Ring Circuit Conductor
Continuity Test Ohm Meter
Disconnect both the supply source cables from mcbfuse
Take readings at earth conductors of both sources and note resistance readings
Live and Neutral Conductor Continuity Test
1 To ensure that each conductor in the circuit has continuity
2 Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
3 Test Method
1 1048766 Switch off the Main switch RCD and MCB
2 1048766 Disconnect all loads
3 1048766 Switch on all switches in the circuit
4 1048766 Disconnect the fusesfinal circuit breakers and close the circuit
5 1048766 Carry out the test as shown in Figure 83
6 1048766 The meter reading value shall be less than 1 ohm Figure 83 - Live and Neutral
Conductor Continuity Test Ohm Meter
Insulation Resistance Test
69 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
i Ensure that there is no leakage current between phase conductors phase and neutral conductors and
phase conductor and earth
ii Test the strength of the cable insulation
iii Test Equipment ndash Insulation Resistance Tester Operating voltage is 250VDC or 500VDC
iv Test Method
1 1048766 Switch off main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in the Table below
5 1048766 Meter reading value shall be less than 1 Megaohm
Polarity Test
i Ensure that each fuse or single pole control and protection device is connected only in the phase
conductor
ii Intermediate contact of Edison screw lamp holder is connected to the phase conductor
iii Ensure that phase neutral and earth conductors at socket outlets are connected at the correct
terminals
iv Test Equipment ndash Multimeter (Ohm range) or Ohm meter
v Test Method
1 1048766 Switch off Main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in Figure 85
5 1048766 Test switches and single phase control devices at the phase conductors
6 1048766 Test socket outlet connection sources
7 1048766 Test Edison screw lamp holder connections
8 1048766 Meter reading value shall be less than 1 Ω
Earth Electrode Resistance Test
i To test the earth electrode resistance
70 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
ii To ascertain the suitability of the location of the electrode
iii To ensure that the electrode is not buried within the resistance area of another electrode
iv Test equipment ndash Earth Resistance Tester
v Test method -
1 1048766 Terminal rsquoErsquo is connected to the electrode to be tested (green conductor)
2 1048766 Terminal lsquoPrsquo is connected to the potential spike (yellow conductor) at a distance of 10
meters from the earth electrode
3 1048766 Terminal lsquoCrsquo is connected to the current spike (red conductor) at a distance of 20 meters
from the earth electrode E P C Electrode 10 meter 10 meter
Figure 86 ndash Earth Electrode Resistance Measurement Test Equipment
Earth Electrode Resistance Measurement Method (Figure 86)
This test must be repeated at least three times to ensure that the reading is not affected by interacting
earthing regions
i Record the first reading (Z1) Example Z1 = 10 Ω
ii Move the voltage spike to a distance of 6 meters from the original position Record the second
reading (Z2) Example Z2 = 10 Ω
iii Move the voltage spike to a distance of 6 meters from the original position Record the third
reading (Z3)
Example Z3 = 10 Ω
Residual Current Device Test
71 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
i Ensure that the residual current device (RCD) trips within the set time on the occurrence of current
leakage to earth
ii Test Equipment ndash RCD Tester RCCB Tester
iii Test Method 1
1 1048766 Use the Trip Test Button
2 1048766 Press the trip button found on the RCD to determine if it trips or otherwise This test would
not be able to determine the sensitivity of the RCD nor the time taken for it to trip
iv Test Method 2
1048766 Use a RCD Tester
This equipment is equipped with a 13A plug which can be connected to a 13A socket outlet Select the
RCD sensitivity to be the same as the sensitivity of the RCD to be tested to determine if the RCD can
trip The time to trip shall not exceed 40 mS
1048766 Test method ndash
a) Position the selection switch in accordance with the sensitivity of the RCD used
Example 100 mA 01 A
b) Position the operations switch to lsquoNo Triprsquo (frac12 Rated mA = 50) connect the 3 pin plug to
the 13A socket outlet
c) Switch on the 13A socket outlet ndash ensure that the P-N and P-E lights light up This shows that
the polarity is correct (Note if both the lights as above do not light up the test cannot be
continued)
d) Press the test button ndash the reading shows less than 200 millisecond and simultaneously the
lsquotestrsquo light lights up and the P-N and P-E lights do not light up At that instant the RCD will
not trip
e) Move the selection switch to 180o (+ve wave) ndash repeat steps (d) and (e) = 100)
f) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
g) Move the selection switch to 0o (-ve wave)
h) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
i) The above test is repeated until a near correct reading is obtained
j) Record the test results
k) Change the operations switch to lsquoFast Triprsquo and press the test button ndash RCD will trip within a
time not exceeding 40 mS
l) Repeat a number of times at 0o or 180o
72 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 9 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (DC)
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
73 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Start stop button 240Vac 5A 2
9 Filament lamp (Bulb ) 240Vac 40W 3
10 Overload Relay 415V 20A 3
11 Three phase induction motor 5 hp 3
12 Single phase step down transformer 2500VA 1
13 Single core PVC insulated Cable 1mm 2 As required
14 Single core PVC insulated Cable 25mm 2 As required
15 DIN rail 35 mm As required
16 PVC type Cable tray 50 mm x 50 mm As required
17 Cable ties 4 ldquo As required
18 Flexible wires 05 mm As required
19 PVC Connectors 5 A amp 20 A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the schematic
diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a optional exercise
i Simple DOL starter
ii Forward reverse DOL starter
iii Forward Reverse Dahlander motor
iv Three motors operated in sequence by DOL starter operated by manual push
button or time delay relay
74 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
a One loop per-cycle
b Continuous operation in a loop
c optional circuit design to represent the same task
v Only one out of three motors to be operated at a time (quiz)
4 Test the functionality of completed project
LESSON 10 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (AC)
75 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 1
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Lamp point 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
76 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
11 Overload Relay 415V 20A 3
12 Three phase induction
motor
5 hp 3
13 Single core PVC insulated
Cable
1mm 2 As required
14 Single core PVC insulated
Cable
25mm 2 As required
15 DIN rail 35 mm As required
16 PVC type Cable tray 50 mm x 50 mm As required
17 Cable ties 4 ldquo As required
18 Flexible wires 05 mm As required
19 PVC Connectors 5 A amp 20 A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the
schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram optional exercise
4 Simple DOL starter
5 Forward reverse DOL starter
6 Test the functionality of completed project
77 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 1
78 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
cm
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Indicating light 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
11 Overload Relay 415V 20A 3
12 Three phase induction motor 5 hp 3
13 Single phase step down
transformer
2500VA 1
14 Single core PVC insulated
Cable
1mm 2 As required
15 Single core PVC insulated
Cable
25mm 2 As required
16 DIN rail 35 mm As required
17 PVC type Cable tray 50 mm x 50 mm As required
18 Cable ties 4 ldquo As required
19 Flexible wires 05 mm As required
20 PVC Connectors 5 A amp 20 A 240 V As required
21 Single pole MCB 6A 240 V 1
22 Single pole MCB 2A 240 V 1
23 Triple pole MCB 20A 415 V 1
24 Mounting board 30 cm x 40 cm x 3
cm
1
25 Relay cw 11 pin socket 10 A 240 Vac 2
26 Time delay relay 10 A 240 Vac 3
27 Triple pole Contactor 20A 240Vac 3
28 Batten type Lamp holder 240Vac 10 A 3
29 Start stop button 240Vac 10A 2
30 Indicating light (Bulb ) 240Vac 25W 3
31 Overload Relay 415V 20A 1
32 Three phase dahlander type
induction motor
5 hp 1
33 Single phase step down
transformer
24024Vac
2500VA
1
79 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
34 Single core PVC insulated
Cable
1mm 2 As required
35 Single core PVC insulated
Cable
25mm 2 As required
36 DIN rail 35 mm As required
37 PVC type Cable tray 50 mm x 50 mm As required
38 Cable ties 4 ldquo As required
39 Flexible wires 075 mm As required
40 PVC Connectors 5 A amp 20 A 240 V As required
41 Terminal block 20A 240Vac As required
Procedures
5 Identify each component according to specification and quantity required from the schematic
diagram attached
6 Test the functionality of each component by using multi-meter or power supply whichever
applicable
7 Wire component according to circuit diagram
8 Three motors operated in sequence by DOL starter operated by manual push button or time
delay relay
a One loop per-cycle
b Continuous operation in a loop
c optional circuit design to represent the same task
d Only one out of three motors to be operated at a time (quiz)
9 Test the functionality of completed project
80 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
BASIC DESIGN INDUSTRIAL MOTOR CONTROL (SEQUENCE CONTROL)
THREE PHASE INDUCTION MOTOR OPERATED IN SEQUENCE BY DIRECT ON LINE
STARTER
LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
81 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
82 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Lcd lamp indicator 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
11 Overload Relay 415V 20A 3
12 Three phase induction motor 5 hp 3
13 Single phase step down transformer 2500VA 1
14 Single core PVC insulated Cable 1mm 2 As required
15 Single core PVC insulated Cable 25mm 2 As required
16 DIN rail 35 mm As required
17 PVC type Cable tray 50 mm x 50 mm As required
18 Cable ties 4 ldquo As required
19 Flexible wires 1 mm Oslash As required
20 PVC Terminal block 10A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the schematic
diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a optional exercise
i Forward Reverse dahlander motor
4 Test the functionality of completed project
83 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
THREE PHASE DAHLANDER TYPE INDUCTION MOTOR OPERATED FORWARD AND
REVERSE OPERATION BY DIRECT ON LINE STARTER
84 ndash 99EASYTECH ENTERPRISE
LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
Introduction
If a motors windings are connected in the star configuration any two phases will be in series across
the supply and hence the line current will be smaller(by 577) than if the windings were connected in
the delta arrangement
Hence larger-type motors with heavy starting currents are first connected in star and then when the
starting currents fall in delta This of course means that all six of the ends of the windings must be
brought to terminations outside the casing (Fig 833)
EZTECH
EZTECH ELECTRICAL INSTALLATION GUIDE
The automatic version of this starter incorporates a timing relay which automatically changes the
connections from star to delta Figs 834 and 835 show the wiring and schematic diagrams for a star
delta starter
Objectives
1 Identify component and the specification
2 Design forward reverse star delta starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
2 ndash 99EASYTECH ENTERPRISE
REV -C
LEGENDMCCB Moulded Case Circuit BreakerTOR Thermal Over Load RelayFOW-C Mains Forward ContactorREV-C Mains Reverse ContactorDC Delta ContactorSC Star ContactorS-SW Mains Selector Switch
SC
V2
W2
U2
DC
V1
W1
U1
TOR
TOR
FOW-C
30A MCCB
TOR
MAIN CIRCUIT FORWARD REVERSE STAR DELTA
RYBN S
-SW
3 PHASEINDUCTION MOTOR
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Relay 10 A 240V 3
5 Triple pole Contactor
6 cw NO NC auxiliary contact
240Vac 20 A 4
7 Overload Relay 415 V 1
8 LED indicator 240vac 5 A 4
9 Start stop button 240Vac 5A 2
10 DIN rail 35 mm As required
11 Flexible wires 1 mm As required
12 Single core PVC insulated
wire
25 mm As required
13 Terminal block 20 A As required
14 Squirrel cage motor 5kW 1
15 5 pin plug and socket 415V 20A 1
16 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
3 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
a Manual star delta
b Manual Forward reverse star delta starter
c Automatic star delta starter
d Automatic Forward reverse star delta starter
4 Test the functionality of completed project
4 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
Objectives
1 Identify component and the specification
2 Design auto transformer starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
5 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Autotransformer starter is used to start a 3 phase induction motor that has a rating between 10 to 15 hp
6 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Autotransformer set 10Kw 415 V 50 Hz 1
5 Triple pole Contactor 240Vac 4
6 Batten type Lamp holder 240 Vac 105 A 4
7 Start stop button 240Vac 10A 4
8 Filament lamp (Bulb ) 240Vac 40W 4
9 DIN rail 35 mm As required
10 Flexible wires 1 mm As required
7 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
11 Single core PVC insulated
wire
25 mm As required
12 Terminal block 20 A As required
13 Squirrel cage motor 10kW 1
14 5 pin plug and socket 415V 20A 1
15 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a open transient autotransformer starter
b close transient autotransformer starter
c Forward reverse autotransformer starter
4 Test the functionality of completed project
8 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
Objectives
1 Identify component and the specification
2 Design rotor resistance starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
9 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Rotor Resistor set 10kW 1
5 Triple pole Contactor 240Vac 20A 4
6 Indicating light 240vac 5 A 4
7 Start stop push button 240Vac 5A 4
8 DIN rail 35 mm As required
9 Flexible wires 1 mm 2 As required
10 Single core PVC insulated wire 25 mm 2 As required
11 Terminal block 20 A As required
12 Slip Ring motor 10kW 1
13 5 pin round 3 phase socket 415V 20A 1
14 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
10 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
4 Test the functionality of completed project
a Dead circuit test b Life circuit test
5 Measure starting and running Amps
LESSON 16
TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
An installation in general will suffer damage
Damage usually occurs on the electric motor control as follows
1 Damage to the main circuit
2 Damage to the control circuit
The cause of the damage
i Overcurrent overload short circuit
ii Leakage current to ground
iii Equipment malfunction
iv The main control circuit
a Trip of main circuit protection devices fire
b Defect of motor terminal such as short circuit fire loose
v The control circuit is not functioning -
a contactor relay relay time overload relay does not work damaged burned
b Loose cable connection disconnected
Detecting and Repairing Damage
Examples of damage are as follows
i Motor does not work
ii Motor function and overload relay trips
iii Motor function but only partially functional control circuit
Methods of detecting damage
Among the known methods necessary to detect damage are as follows
1 Turn off the electricity at the main switch (main switch) in order to avoid any danger during the
work carried out to detect damage
2 Check all the protective gear that controls the motor control main circuit
11 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
3 Make sure the damage function control circuit
4 Check the control circuit according to the schematic circuit diagram of the motor control
5 Check the operation of the control circuit
Note
Use wiring that has been installed on the SYSTEM OF MOTOR CONTROL BOARD by Forward
Reverse control circuit for Star Delta to test and look for damage
SELF-ASSESSMENT QUESTIONS
1 (a) Explain what is meant by the term lsquoback emfrsquo in a motor
(b) Outline the basic differences between series shunt and compound wound dc motors
2 (a) With the aid of diagrams explain how the speed of series shunt and compound-wound motors
may be controlled
(b) A 440V dc shunt-wound motor has a field resistance of 200R and an armature resistance of 06 R
When its speed is 20 rev d second the current drawn from the supply is 122A Calculate its back
emf at this speed If the speed were decreased to 19 revssecond the field flux remaining unchanged
calculate the new back emf and the new armature current
3 A load of 64 kW at 240 V is supplied from the terminals of a shunt-wound dc generator The field
resistance is 180 A Calculate the armature current
4 (a) Explain with the aid of a diagram how a rotating magnetic field may be
(b) What is meant by lsquosynchronous speedrsquo
Calculate the synchronous obtained speed of a 12 pole motor if the supply frequency is 50Hz
5 (a) Explain the action of a synchronous motor
(b) What methods are available to start a synchronous motor Explain with diagrams
6 (a) Explain the action of a cage induction motor
(b) What is meant by the term lsquosliprsquo
Calculate the percentage slip of a six pole induction motor running at 162 revssecond from a 50 Hz
supply
7 Describe with sketches three different ways of starting a single-phase induction motor
12 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
8 Explain with the aid of a sketch the action of a three-phase DOL starter
What are dashpots used for How are remote start and stop buttons connected
9 A I0 kW 240V 50Hz single-phase cage rotor induction motor is 85efficient and has a PF of 068
lagging Calculate the motor current and the value of capacitor required to raise the PF to 093
lagging
10 Calculate the torque developed by an 18 kW four-pole induction motor run at 35 slip from a
50Hz supply
APPENDIX 1
13 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 11
14 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 111
Attachment Reference
httpswwwtlc-directcoukBook621htm
httpwwwstgovmyindexphpms
15 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
4 Test the functionality of completed project
LESSON 6 ndash WIRING SYSTEM OF 3 Oslash DISTRIBUTION BOARD
Introduction
44 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
45 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
46 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
47 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
48 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify each component and the specification
2 Wire component according to the schematic diagram given
3 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting Board 450 x 600 mm Perforated metal 1
2 5 pin round socket and plug 415V ac 32A 1
3 Cut out fuse 60 A 3
4 Neutral link 1
5 kWatt hour meter 415V 60A 1
6 ELCB RCCB 3P+N In=63A415 Vac I trip= 300mA 1
7 ELCB RCCB 3P+N In=63A415 Vac I trip= 30mA 1
8 Single pole MCB 6A 240 V 3
9 Single pole MCB 20A 240 V 3
10 DOL starter 20 A 240Vac 2
11 Socket outlet 15 A 240 Vac 1
12 Switched Socket outlet 13 A 240 Vac 3
13 Led indicating light 5A 240 Vac 3
14 Single pole 4 gang 1 way switch 5A 240 Vac 2
15 Single pole 2 way switch 5A 240 Vac 2
16 1 phase induction motor 1 kW 240Vac 1
17 Metal trunking 30 mm x30 mm As required
18 Self tapping Wood screw 4 mm x 20 mm As required
19 DIN rail 25 mm x 1mm
20 GI steel rigid conduit 20mm As required
21 Flexible conduit 20mm As required
22 End box 20 mm 4
23 Flexible wires 05 mm 2 As required
24 Single core PVC insulated wire 15 mm 2 As required
25 Single core PVC insulated wires 25 mm 2 As required
26 Terminal block 10 A As required
Procedures
49 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify each components and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
4 Test the functionality of completed project
1 dead circuit test
2 life circuit
Note Proper earthing should be made
50 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 7 ndash WIRING SYSTEM OF THREE PHASE LIGHTING AND POWER CIRCUIT
51 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
52 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify component and the specification
2 Wire component according to the schematic diagram
3 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting bay Board Perforated metal 180 cm x 180 cm 1
2 k Watt hour meter 415V 60A 1
3 MCCB 415V 60A
4 ELCB RCCB In=60A415 Vac I trip=30mA 1
5 5 pin round Socket and
plug
415Vac 32A 4
6 Single pole MCB 6A 1
7 Triple pole MCB 20A 2
8 Triple pole Main switch 60A 1
9 DOL starter 240Vac 2
10 3 phase induction motor 2hp 415 Vac 1
11 1 phase induction motor 1
12 Metal trunking 30 mm x30 mm As required
13 Self tapping Wood screw 4 mm x 20 mm As required
14 DIN rail 25 mm x 1mm
15 GI steel rigid conduit 20mm As required
16 Flexible conduit 20mm As required
17 End box 20 mm 4
18 Flexible wires 05 mm As required
19 Connectors 10 A As required
Procedures
1 Identify each components and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
4 Test the functionality of completed project
1 dead circuit 2 life circuit test
5 Record the current drawn by the load as connected in star and delta
Note Proper earthing should be made
53 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 8 INSPECTION AND TESTING OF ELECTRICAL INSTALLATION
On completion of a wiring installation a number of tests on the installation have to be conducted to
ascertain that the wiring circuits and connected appliances are safe for use Prior to carrying out the
tests an inspection has to be done The results of the inspectionsupervision and test have to be
presented in Form G (as in Appendix IV) and Form H (as in Appendix V)
To have the test certification as in Form H the following tests shall be conducted
i Continuity Test
ii Insulation Resistance Test
iii Polarity Test
iv Earth Electrode Resistance test and
v Residual Current Device Test
1 Continuity Test
There are 3 main types of continuity tests for the final circuits-
i Protection Conductor Continuity Test
ii Final Ring Circuit Conductor Continuity Test
iii Live and Neutral Conductor Continuity Test
a) Protection Conductor Continuity Test
bull To ascertain that all protection conductors are connected in the correct and effective manner
bull Test equipment ndash Multimeter (Ohm range) or Ohm meter
54 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
bull Test Method
1 1048766 Ensure that the main switch RCD and MCB are open circuited (switched off) and all loads
are disconnected
2 1048766 Connected the test leads as in the Figure 81 The meter reading shall be less than 1 Ω
55 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Final Ring Circuit Conductor Continuity Test
bull To ensure that all conductors around the ring circuit have continuity
bull Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
bull Test Method
1 1048766 Disconnect both the supply source live conductors from the MCB the neutral conductor
from the neutral terminals and the earth conductor from the earth terminal in the distribution
fuse box
2 1048766 Connect the test leads as in the Figure 82 (EE)
3 1048766 Repeat the procedure for (L-L) and (N-N)
4 1048766 The meter reading value shall be less than 1 ohm
56 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Live and Neutral Conductor Continuity Test
a To ensure that each conductor in the circuit has continuity
b Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
2 Test Method
1 1048766 Switch off the Main switch RCD and MCB
2 1048766 Disconnect all loads
3 1048766 Switch on all switches in the circuit
4 1048766 Disconnect the fusesfinal circuit breakers and close the circuit
5 1048766 Carry out the test as shown in Figure 83
6 1048766 The meter reading value shall be less than 1Ω
57 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
58 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
CONTINUITY TEST
Insulation Resistance Test
i Ensure that there is no leakage current between phase conductors phase and neutral conductors and
phase conductor and earth
ii Test the strength of the cable insulation
iii Test Equipment ndash Insulation Resistance Tester operating voltage is 250VDC or 500VDC
iv Test Method
1 1048766 Switch off main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
59 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
4 1048766 Carry out test as in the Table below
5 1048766 Meter reading value shall be less than 1 Megaohm
60 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
61 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Insulation resitance test
62 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
INSULATION RESISTANCE TEST BETWEEN CONDUCTORS AND OPPOSITE POLARITY
Polarity Testi Ensure that each fuse or single pole control and protection device is connected only in the phase
conductor
ii Intermediate contact of Edison screw lamp holder is connected to the phase conductor
iii Ensure that phase neutral and earth conductors at socket outlets are connected at the correct
terminals
iv Test Equipment ndash Multimeter (Ohm range) or Ohm meter
v Test Method
1 1048766 Switch off Main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in Figure 85
63 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
5 1048766 Test switches and single phase control devices at the phase conductors
6 1048766 Test socket outlet connection sources
7 1048766 Test Edison screw lamp holder connections
8 1048766 Meter reading value shall be less than 1 Ω
64 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Polarity test
65 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Earth Electrode Resistance Testi To test the earth electrode resistance
ii To ascertain the suitability of the location of the electrode
iii To ensure that the electrode is not buried within the resistance area of another electrode
iv Test equipment ndash Earth Resistance Tester
v Test method -
1 1048766 Terminal rsquoErsquo is connected to the electrode to be tested (green conductor)
2 1048766 Terminal lsquoPrsquo is connected to the potential spike (yellow conductor) at a distance of 10
meters from the earth electrode
3 1048766 Terminal lsquoCrsquo is connected to the current spike (red conductor) at a distance of 20 meters
from the earth electrode
Earth Electrode Resistance Measurement Method (Figure 86)
This test must be repeated at least three times to ensure that the reading is not affected by interacting
earthing regions
i Record the first reading (Z1) Example Z1 = 10 Ω
ii Move the voltage spike to a distance of 6 meters from the original position Record the second
reading (Z2 ) Example Z2 = 10 Ω
iii Move the voltage spike to a distance of 6 meters from the original position Record the third
reading (Z3) Example Z3 = 10 Ω
66 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Residual Current Device Testi Ensure that the residual current device (RCD) trips within the set time on the occurrence of current
leakage to earth
ii Test Equipment ndash RCD Tester RCCB Tester
iii Test Method 1
1 1048766 Use the Trip Test Button
2 1048766 Press the trip button found on the RCD to determine if it trips or otherwise This test would
not be able to determine the sensitivity of the RCD nor the time taken for it to trip
iv Test Method 2
i 1048766 Use a RCD Tester
ii This equipment is equipped with a 13A plug which can be connected to a 13A socket outlet
Select the RCD sensitivity to be the same as the sensitivity of the RCD to be tested to
determine if the RCD can trip The time to trip shall not exceed 40 mS
iii 1048766 Test method ndash
a) Position the selection switch in accordance with the sensitivity of the RCD used
Example 100 mA 01 A
b) Position the operations switch to lsquoNo Triprsquo (frac12 Rated mA = 50) connect the 3 pin plug to
the 13A socket outlet
67 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
c) Switch on the 13A socket outlet ndash ensure that the P-N and P-E lights light up
This shows that the polarity is correct (Note if both the lights as above do not light up the test cannot
be continued)
d) Press the test button ndash the reading shows less than 200 mS and simultaneously the lsquotestrsquo light lights
up and the P-N and P-E lights do not light up At that instant the RCD will not trip
e) Move the selection switch to 180o (+ve wave) ndash repeat steps (d) and (e) Move the operations
switch to lsquoTriprsquo (Rated mA = 100)
g) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200mS
h) Move the selection switch to 0o (-ve wave)
i) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
j) The above test is repeated until a near correct reading is obtained
k) Record the test results
l) Change the operations switch to lsquoFast Triprsquo and press the test button ndash RCD will trip within a
time not exceeding 40 millisecond
m) Repeat a number of times at 0o or 180o
On completion of a wiring installation a number of tests on the installation have to be conducted to
ascertain that the wiring circuits and connected appliances are safe for use Prior to carrying out the
tests an inspection has to be done the following tests shall be conducted
i Continuity Test
ii Insulation Resistance Test
iii Polarity Test
iv Earth Electrode Resistance test and
v Residual Current Device Test
821 Continuity Test
There are 3 main types of continuity tests for the final circuits-
i Protection Conductor Continuity Test
ii Final Ring Circuit Conductor Continuity Test
68 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
iii Live and Neutral Conductor Continuity Test
a) Protection Conductor Continuity Test
bull To ascertain that all protection conductors are connected in the correct and effective manner
bull Test equipment ndash Multimeter (Ohm range) or Ohm meter
bull Test Method
1 1048766 Ensure that the main switch RCD and MCB are open circuited (switched off) and all loads are
disconnected
2 1048766 Connected the test leads as in the Figure 81
3 1048766 The meter reading shall be less than 1 Ω
Final Ring Circuit Conductor Continuity Test
bull To ensure that all conductors around the ring circuit have continuity
bull Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
bull Test Method
1 1048766 Disconnect both the supply source live conductors from the MCB the neutral conductor
from the neutral terminals and the earth conductor from the earth terminal in the distribution
fuse box
2 1048766 Connect the test leads as in the Figure 82 (EE)
3 1048766 Repeat the procedure for (L-L) and (N-N)
4 1048766 The meter reading value shall be less than 1 ohm Figure 82 - Final Ring Circuit Conductor
Continuity Test Ohm Meter
Disconnect both the supply source cables from mcbfuse
Take readings at earth conductors of both sources and note resistance readings
Live and Neutral Conductor Continuity Test
1 To ensure that each conductor in the circuit has continuity
2 Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
3 Test Method
1 1048766 Switch off the Main switch RCD and MCB
2 1048766 Disconnect all loads
3 1048766 Switch on all switches in the circuit
4 1048766 Disconnect the fusesfinal circuit breakers and close the circuit
5 1048766 Carry out the test as shown in Figure 83
6 1048766 The meter reading value shall be less than 1 ohm Figure 83 - Live and Neutral
Conductor Continuity Test Ohm Meter
Insulation Resistance Test
69 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
i Ensure that there is no leakage current between phase conductors phase and neutral conductors and
phase conductor and earth
ii Test the strength of the cable insulation
iii Test Equipment ndash Insulation Resistance Tester Operating voltage is 250VDC or 500VDC
iv Test Method
1 1048766 Switch off main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in the Table below
5 1048766 Meter reading value shall be less than 1 Megaohm
Polarity Test
i Ensure that each fuse or single pole control and protection device is connected only in the phase
conductor
ii Intermediate contact of Edison screw lamp holder is connected to the phase conductor
iii Ensure that phase neutral and earth conductors at socket outlets are connected at the correct
terminals
iv Test Equipment ndash Multimeter (Ohm range) or Ohm meter
v Test Method
1 1048766 Switch off Main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in Figure 85
5 1048766 Test switches and single phase control devices at the phase conductors
6 1048766 Test socket outlet connection sources
7 1048766 Test Edison screw lamp holder connections
8 1048766 Meter reading value shall be less than 1 Ω
Earth Electrode Resistance Test
i To test the earth electrode resistance
70 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
ii To ascertain the suitability of the location of the electrode
iii To ensure that the electrode is not buried within the resistance area of another electrode
iv Test equipment ndash Earth Resistance Tester
v Test method -
1 1048766 Terminal rsquoErsquo is connected to the electrode to be tested (green conductor)
2 1048766 Terminal lsquoPrsquo is connected to the potential spike (yellow conductor) at a distance of 10
meters from the earth electrode
3 1048766 Terminal lsquoCrsquo is connected to the current spike (red conductor) at a distance of 20 meters
from the earth electrode E P C Electrode 10 meter 10 meter
Figure 86 ndash Earth Electrode Resistance Measurement Test Equipment
Earth Electrode Resistance Measurement Method (Figure 86)
This test must be repeated at least three times to ensure that the reading is not affected by interacting
earthing regions
i Record the first reading (Z1) Example Z1 = 10 Ω
ii Move the voltage spike to a distance of 6 meters from the original position Record the second
reading (Z2) Example Z2 = 10 Ω
iii Move the voltage spike to a distance of 6 meters from the original position Record the third
reading (Z3)
Example Z3 = 10 Ω
Residual Current Device Test
71 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
i Ensure that the residual current device (RCD) trips within the set time on the occurrence of current
leakage to earth
ii Test Equipment ndash RCD Tester RCCB Tester
iii Test Method 1
1 1048766 Use the Trip Test Button
2 1048766 Press the trip button found on the RCD to determine if it trips or otherwise This test would
not be able to determine the sensitivity of the RCD nor the time taken for it to trip
iv Test Method 2
1048766 Use a RCD Tester
This equipment is equipped with a 13A plug which can be connected to a 13A socket outlet Select the
RCD sensitivity to be the same as the sensitivity of the RCD to be tested to determine if the RCD can
trip The time to trip shall not exceed 40 mS
1048766 Test method ndash
a) Position the selection switch in accordance with the sensitivity of the RCD used
Example 100 mA 01 A
b) Position the operations switch to lsquoNo Triprsquo (frac12 Rated mA = 50) connect the 3 pin plug to
the 13A socket outlet
c) Switch on the 13A socket outlet ndash ensure that the P-N and P-E lights light up This shows that
the polarity is correct (Note if both the lights as above do not light up the test cannot be
continued)
d) Press the test button ndash the reading shows less than 200 millisecond and simultaneously the
lsquotestrsquo light lights up and the P-N and P-E lights do not light up At that instant the RCD will
not trip
e) Move the selection switch to 180o (+ve wave) ndash repeat steps (d) and (e) = 100)
f) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
g) Move the selection switch to 0o (-ve wave)
h) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
i) The above test is repeated until a near correct reading is obtained
j) Record the test results
k) Change the operations switch to lsquoFast Triprsquo and press the test button ndash RCD will trip within a
time not exceeding 40 mS
l) Repeat a number of times at 0o or 180o
72 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 9 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (DC)
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
73 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Start stop button 240Vac 5A 2
9 Filament lamp (Bulb ) 240Vac 40W 3
10 Overload Relay 415V 20A 3
11 Three phase induction motor 5 hp 3
12 Single phase step down transformer 2500VA 1
13 Single core PVC insulated Cable 1mm 2 As required
14 Single core PVC insulated Cable 25mm 2 As required
15 DIN rail 35 mm As required
16 PVC type Cable tray 50 mm x 50 mm As required
17 Cable ties 4 ldquo As required
18 Flexible wires 05 mm As required
19 PVC Connectors 5 A amp 20 A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the schematic
diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a optional exercise
i Simple DOL starter
ii Forward reverse DOL starter
iii Forward Reverse Dahlander motor
iv Three motors operated in sequence by DOL starter operated by manual push
button or time delay relay
74 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
a One loop per-cycle
b Continuous operation in a loop
c optional circuit design to represent the same task
v Only one out of three motors to be operated at a time (quiz)
4 Test the functionality of completed project
LESSON 10 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (AC)
75 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 1
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Lamp point 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
76 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
11 Overload Relay 415V 20A 3
12 Three phase induction
motor
5 hp 3
13 Single core PVC insulated
Cable
1mm 2 As required
14 Single core PVC insulated
Cable
25mm 2 As required
15 DIN rail 35 mm As required
16 PVC type Cable tray 50 mm x 50 mm As required
17 Cable ties 4 ldquo As required
18 Flexible wires 05 mm As required
19 PVC Connectors 5 A amp 20 A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the
schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram optional exercise
4 Simple DOL starter
5 Forward reverse DOL starter
6 Test the functionality of completed project
77 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 1
78 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
cm
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Indicating light 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
11 Overload Relay 415V 20A 3
12 Three phase induction motor 5 hp 3
13 Single phase step down
transformer
2500VA 1
14 Single core PVC insulated
Cable
1mm 2 As required
15 Single core PVC insulated
Cable
25mm 2 As required
16 DIN rail 35 mm As required
17 PVC type Cable tray 50 mm x 50 mm As required
18 Cable ties 4 ldquo As required
19 Flexible wires 05 mm As required
20 PVC Connectors 5 A amp 20 A 240 V As required
21 Single pole MCB 6A 240 V 1
22 Single pole MCB 2A 240 V 1
23 Triple pole MCB 20A 415 V 1
24 Mounting board 30 cm x 40 cm x 3
cm
1
25 Relay cw 11 pin socket 10 A 240 Vac 2
26 Time delay relay 10 A 240 Vac 3
27 Triple pole Contactor 20A 240Vac 3
28 Batten type Lamp holder 240Vac 10 A 3
29 Start stop button 240Vac 10A 2
30 Indicating light (Bulb ) 240Vac 25W 3
31 Overload Relay 415V 20A 1
32 Three phase dahlander type
induction motor
5 hp 1
33 Single phase step down
transformer
24024Vac
2500VA
1
79 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
34 Single core PVC insulated
Cable
1mm 2 As required
35 Single core PVC insulated
Cable
25mm 2 As required
36 DIN rail 35 mm As required
37 PVC type Cable tray 50 mm x 50 mm As required
38 Cable ties 4 ldquo As required
39 Flexible wires 075 mm As required
40 PVC Connectors 5 A amp 20 A 240 V As required
41 Terminal block 20A 240Vac As required
Procedures
5 Identify each component according to specification and quantity required from the schematic
diagram attached
6 Test the functionality of each component by using multi-meter or power supply whichever
applicable
7 Wire component according to circuit diagram
8 Three motors operated in sequence by DOL starter operated by manual push button or time
delay relay
a One loop per-cycle
b Continuous operation in a loop
c optional circuit design to represent the same task
d Only one out of three motors to be operated at a time (quiz)
9 Test the functionality of completed project
80 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
BASIC DESIGN INDUSTRIAL MOTOR CONTROL (SEQUENCE CONTROL)
THREE PHASE INDUCTION MOTOR OPERATED IN SEQUENCE BY DIRECT ON LINE
STARTER
LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
81 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
82 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Lcd lamp indicator 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
11 Overload Relay 415V 20A 3
12 Three phase induction motor 5 hp 3
13 Single phase step down transformer 2500VA 1
14 Single core PVC insulated Cable 1mm 2 As required
15 Single core PVC insulated Cable 25mm 2 As required
16 DIN rail 35 mm As required
17 PVC type Cable tray 50 mm x 50 mm As required
18 Cable ties 4 ldquo As required
19 Flexible wires 1 mm Oslash As required
20 PVC Terminal block 10A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the schematic
diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a optional exercise
i Forward Reverse dahlander motor
4 Test the functionality of completed project
83 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
THREE PHASE DAHLANDER TYPE INDUCTION MOTOR OPERATED FORWARD AND
REVERSE OPERATION BY DIRECT ON LINE STARTER
84 ndash 99EASYTECH ENTERPRISE
LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
Introduction
If a motors windings are connected in the star configuration any two phases will be in series across
the supply and hence the line current will be smaller(by 577) than if the windings were connected in
the delta arrangement
Hence larger-type motors with heavy starting currents are first connected in star and then when the
starting currents fall in delta This of course means that all six of the ends of the windings must be
brought to terminations outside the casing (Fig 833)
EZTECH
EZTECH ELECTRICAL INSTALLATION GUIDE
The automatic version of this starter incorporates a timing relay which automatically changes the
connections from star to delta Figs 834 and 835 show the wiring and schematic diagrams for a star
delta starter
Objectives
1 Identify component and the specification
2 Design forward reverse star delta starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
2 ndash 99EASYTECH ENTERPRISE
REV -C
LEGENDMCCB Moulded Case Circuit BreakerTOR Thermal Over Load RelayFOW-C Mains Forward ContactorREV-C Mains Reverse ContactorDC Delta ContactorSC Star ContactorS-SW Mains Selector Switch
SC
V2
W2
U2
DC
V1
W1
U1
TOR
TOR
FOW-C
30A MCCB
TOR
MAIN CIRCUIT FORWARD REVERSE STAR DELTA
RYBN S
-SW
3 PHASEINDUCTION MOTOR
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Relay 10 A 240V 3
5 Triple pole Contactor
6 cw NO NC auxiliary contact
240Vac 20 A 4
7 Overload Relay 415 V 1
8 LED indicator 240vac 5 A 4
9 Start stop button 240Vac 5A 2
10 DIN rail 35 mm As required
11 Flexible wires 1 mm As required
12 Single core PVC insulated
wire
25 mm As required
13 Terminal block 20 A As required
14 Squirrel cage motor 5kW 1
15 5 pin plug and socket 415V 20A 1
16 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
3 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
a Manual star delta
b Manual Forward reverse star delta starter
c Automatic star delta starter
d Automatic Forward reverse star delta starter
4 Test the functionality of completed project
4 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
Objectives
1 Identify component and the specification
2 Design auto transformer starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
5 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Autotransformer starter is used to start a 3 phase induction motor that has a rating between 10 to 15 hp
6 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Autotransformer set 10Kw 415 V 50 Hz 1
5 Triple pole Contactor 240Vac 4
6 Batten type Lamp holder 240 Vac 105 A 4
7 Start stop button 240Vac 10A 4
8 Filament lamp (Bulb ) 240Vac 40W 4
9 DIN rail 35 mm As required
10 Flexible wires 1 mm As required
7 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
11 Single core PVC insulated
wire
25 mm As required
12 Terminal block 20 A As required
13 Squirrel cage motor 10kW 1
14 5 pin plug and socket 415V 20A 1
15 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a open transient autotransformer starter
b close transient autotransformer starter
c Forward reverse autotransformer starter
4 Test the functionality of completed project
8 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
Objectives
1 Identify component and the specification
2 Design rotor resistance starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
9 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Rotor Resistor set 10kW 1
5 Triple pole Contactor 240Vac 20A 4
6 Indicating light 240vac 5 A 4
7 Start stop push button 240Vac 5A 4
8 DIN rail 35 mm As required
9 Flexible wires 1 mm 2 As required
10 Single core PVC insulated wire 25 mm 2 As required
11 Terminal block 20 A As required
12 Slip Ring motor 10kW 1
13 5 pin round 3 phase socket 415V 20A 1
14 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
10 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
4 Test the functionality of completed project
a Dead circuit test b Life circuit test
5 Measure starting and running Amps
LESSON 16
TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
An installation in general will suffer damage
Damage usually occurs on the electric motor control as follows
1 Damage to the main circuit
2 Damage to the control circuit
The cause of the damage
i Overcurrent overload short circuit
ii Leakage current to ground
iii Equipment malfunction
iv The main control circuit
a Trip of main circuit protection devices fire
b Defect of motor terminal such as short circuit fire loose
v The control circuit is not functioning -
a contactor relay relay time overload relay does not work damaged burned
b Loose cable connection disconnected
Detecting and Repairing Damage
Examples of damage are as follows
i Motor does not work
ii Motor function and overload relay trips
iii Motor function but only partially functional control circuit
Methods of detecting damage
Among the known methods necessary to detect damage are as follows
1 Turn off the electricity at the main switch (main switch) in order to avoid any danger during the
work carried out to detect damage
2 Check all the protective gear that controls the motor control main circuit
11 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
3 Make sure the damage function control circuit
4 Check the control circuit according to the schematic circuit diagram of the motor control
5 Check the operation of the control circuit
Note
Use wiring that has been installed on the SYSTEM OF MOTOR CONTROL BOARD by Forward
Reverse control circuit for Star Delta to test and look for damage
SELF-ASSESSMENT QUESTIONS
1 (a) Explain what is meant by the term lsquoback emfrsquo in a motor
(b) Outline the basic differences between series shunt and compound wound dc motors
2 (a) With the aid of diagrams explain how the speed of series shunt and compound-wound motors
may be controlled
(b) A 440V dc shunt-wound motor has a field resistance of 200R and an armature resistance of 06 R
When its speed is 20 rev d second the current drawn from the supply is 122A Calculate its back
emf at this speed If the speed were decreased to 19 revssecond the field flux remaining unchanged
calculate the new back emf and the new armature current
3 A load of 64 kW at 240 V is supplied from the terminals of a shunt-wound dc generator The field
resistance is 180 A Calculate the armature current
4 (a) Explain with the aid of a diagram how a rotating magnetic field may be
(b) What is meant by lsquosynchronous speedrsquo
Calculate the synchronous obtained speed of a 12 pole motor if the supply frequency is 50Hz
5 (a) Explain the action of a synchronous motor
(b) What methods are available to start a synchronous motor Explain with diagrams
6 (a) Explain the action of a cage induction motor
(b) What is meant by the term lsquosliprsquo
Calculate the percentage slip of a six pole induction motor running at 162 revssecond from a 50 Hz
supply
7 Describe with sketches three different ways of starting a single-phase induction motor
12 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
8 Explain with the aid of a sketch the action of a three-phase DOL starter
What are dashpots used for How are remote start and stop buttons connected
9 A I0 kW 240V 50Hz single-phase cage rotor induction motor is 85efficient and has a PF of 068
lagging Calculate the motor current and the value of capacitor required to raise the PF to 093
lagging
10 Calculate the torque developed by an 18 kW four-pole induction motor run at 35 slip from a
50Hz supply
APPENDIX 1
13 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 11
14 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 111
Attachment Reference
httpswwwtlc-directcoukBook621htm
httpwwwstgovmyindexphpms
15 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
45 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
46 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
47 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
48 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify each component and the specification
2 Wire component according to the schematic diagram given
3 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting Board 450 x 600 mm Perforated metal 1
2 5 pin round socket and plug 415V ac 32A 1
3 Cut out fuse 60 A 3
4 Neutral link 1
5 kWatt hour meter 415V 60A 1
6 ELCB RCCB 3P+N In=63A415 Vac I trip= 300mA 1
7 ELCB RCCB 3P+N In=63A415 Vac I trip= 30mA 1
8 Single pole MCB 6A 240 V 3
9 Single pole MCB 20A 240 V 3
10 DOL starter 20 A 240Vac 2
11 Socket outlet 15 A 240 Vac 1
12 Switched Socket outlet 13 A 240 Vac 3
13 Led indicating light 5A 240 Vac 3
14 Single pole 4 gang 1 way switch 5A 240 Vac 2
15 Single pole 2 way switch 5A 240 Vac 2
16 1 phase induction motor 1 kW 240Vac 1
17 Metal trunking 30 mm x30 mm As required
18 Self tapping Wood screw 4 mm x 20 mm As required
19 DIN rail 25 mm x 1mm
20 GI steel rigid conduit 20mm As required
21 Flexible conduit 20mm As required
22 End box 20 mm 4
23 Flexible wires 05 mm 2 As required
24 Single core PVC insulated wire 15 mm 2 As required
25 Single core PVC insulated wires 25 mm 2 As required
26 Terminal block 10 A As required
Procedures
49 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify each components and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
4 Test the functionality of completed project
1 dead circuit test
2 life circuit
Note Proper earthing should be made
50 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 7 ndash WIRING SYSTEM OF THREE PHASE LIGHTING AND POWER CIRCUIT
51 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
52 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify component and the specification
2 Wire component according to the schematic diagram
3 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting bay Board Perforated metal 180 cm x 180 cm 1
2 k Watt hour meter 415V 60A 1
3 MCCB 415V 60A
4 ELCB RCCB In=60A415 Vac I trip=30mA 1
5 5 pin round Socket and
plug
415Vac 32A 4
6 Single pole MCB 6A 1
7 Triple pole MCB 20A 2
8 Triple pole Main switch 60A 1
9 DOL starter 240Vac 2
10 3 phase induction motor 2hp 415 Vac 1
11 1 phase induction motor 1
12 Metal trunking 30 mm x30 mm As required
13 Self tapping Wood screw 4 mm x 20 mm As required
14 DIN rail 25 mm x 1mm
15 GI steel rigid conduit 20mm As required
16 Flexible conduit 20mm As required
17 End box 20 mm 4
18 Flexible wires 05 mm As required
19 Connectors 10 A As required
Procedures
1 Identify each components and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
4 Test the functionality of completed project
1 dead circuit 2 life circuit test
5 Record the current drawn by the load as connected in star and delta
Note Proper earthing should be made
53 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 8 INSPECTION AND TESTING OF ELECTRICAL INSTALLATION
On completion of a wiring installation a number of tests on the installation have to be conducted to
ascertain that the wiring circuits and connected appliances are safe for use Prior to carrying out the
tests an inspection has to be done The results of the inspectionsupervision and test have to be
presented in Form G (as in Appendix IV) and Form H (as in Appendix V)
To have the test certification as in Form H the following tests shall be conducted
i Continuity Test
ii Insulation Resistance Test
iii Polarity Test
iv Earth Electrode Resistance test and
v Residual Current Device Test
1 Continuity Test
There are 3 main types of continuity tests for the final circuits-
i Protection Conductor Continuity Test
ii Final Ring Circuit Conductor Continuity Test
iii Live and Neutral Conductor Continuity Test
a) Protection Conductor Continuity Test
bull To ascertain that all protection conductors are connected in the correct and effective manner
bull Test equipment ndash Multimeter (Ohm range) or Ohm meter
54 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
bull Test Method
1 1048766 Ensure that the main switch RCD and MCB are open circuited (switched off) and all loads
are disconnected
2 1048766 Connected the test leads as in the Figure 81 The meter reading shall be less than 1 Ω
55 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Final Ring Circuit Conductor Continuity Test
bull To ensure that all conductors around the ring circuit have continuity
bull Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
bull Test Method
1 1048766 Disconnect both the supply source live conductors from the MCB the neutral conductor
from the neutral terminals and the earth conductor from the earth terminal in the distribution
fuse box
2 1048766 Connect the test leads as in the Figure 82 (EE)
3 1048766 Repeat the procedure for (L-L) and (N-N)
4 1048766 The meter reading value shall be less than 1 ohm
56 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Live and Neutral Conductor Continuity Test
a To ensure that each conductor in the circuit has continuity
b Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
2 Test Method
1 1048766 Switch off the Main switch RCD and MCB
2 1048766 Disconnect all loads
3 1048766 Switch on all switches in the circuit
4 1048766 Disconnect the fusesfinal circuit breakers and close the circuit
5 1048766 Carry out the test as shown in Figure 83
6 1048766 The meter reading value shall be less than 1Ω
57 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
58 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
CONTINUITY TEST
Insulation Resistance Test
i Ensure that there is no leakage current between phase conductors phase and neutral conductors and
phase conductor and earth
ii Test the strength of the cable insulation
iii Test Equipment ndash Insulation Resistance Tester operating voltage is 250VDC or 500VDC
iv Test Method
1 1048766 Switch off main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
59 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
4 1048766 Carry out test as in the Table below
5 1048766 Meter reading value shall be less than 1 Megaohm
60 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
61 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Insulation resitance test
62 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
INSULATION RESISTANCE TEST BETWEEN CONDUCTORS AND OPPOSITE POLARITY
Polarity Testi Ensure that each fuse or single pole control and protection device is connected only in the phase
conductor
ii Intermediate contact of Edison screw lamp holder is connected to the phase conductor
iii Ensure that phase neutral and earth conductors at socket outlets are connected at the correct
terminals
iv Test Equipment ndash Multimeter (Ohm range) or Ohm meter
v Test Method
1 1048766 Switch off Main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in Figure 85
63 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
5 1048766 Test switches and single phase control devices at the phase conductors
6 1048766 Test socket outlet connection sources
7 1048766 Test Edison screw lamp holder connections
8 1048766 Meter reading value shall be less than 1 Ω
64 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Polarity test
65 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Earth Electrode Resistance Testi To test the earth electrode resistance
ii To ascertain the suitability of the location of the electrode
iii To ensure that the electrode is not buried within the resistance area of another electrode
iv Test equipment ndash Earth Resistance Tester
v Test method -
1 1048766 Terminal rsquoErsquo is connected to the electrode to be tested (green conductor)
2 1048766 Terminal lsquoPrsquo is connected to the potential spike (yellow conductor) at a distance of 10
meters from the earth electrode
3 1048766 Terminal lsquoCrsquo is connected to the current spike (red conductor) at a distance of 20 meters
from the earth electrode
Earth Electrode Resistance Measurement Method (Figure 86)
This test must be repeated at least three times to ensure that the reading is not affected by interacting
earthing regions
i Record the first reading (Z1) Example Z1 = 10 Ω
ii Move the voltage spike to a distance of 6 meters from the original position Record the second
reading (Z2 ) Example Z2 = 10 Ω
iii Move the voltage spike to a distance of 6 meters from the original position Record the third
reading (Z3) Example Z3 = 10 Ω
66 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Residual Current Device Testi Ensure that the residual current device (RCD) trips within the set time on the occurrence of current
leakage to earth
ii Test Equipment ndash RCD Tester RCCB Tester
iii Test Method 1
1 1048766 Use the Trip Test Button
2 1048766 Press the trip button found on the RCD to determine if it trips or otherwise This test would
not be able to determine the sensitivity of the RCD nor the time taken for it to trip
iv Test Method 2
i 1048766 Use a RCD Tester
ii This equipment is equipped with a 13A plug which can be connected to a 13A socket outlet
Select the RCD sensitivity to be the same as the sensitivity of the RCD to be tested to
determine if the RCD can trip The time to trip shall not exceed 40 mS
iii 1048766 Test method ndash
a) Position the selection switch in accordance with the sensitivity of the RCD used
Example 100 mA 01 A
b) Position the operations switch to lsquoNo Triprsquo (frac12 Rated mA = 50) connect the 3 pin plug to
the 13A socket outlet
67 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
c) Switch on the 13A socket outlet ndash ensure that the P-N and P-E lights light up
This shows that the polarity is correct (Note if both the lights as above do not light up the test cannot
be continued)
d) Press the test button ndash the reading shows less than 200 mS and simultaneously the lsquotestrsquo light lights
up and the P-N and P-E lights do not light up At that instant the RCD will not trip
e) Move the selection switch to 180o (+ve wave) ndash repeat steps (d) and (e) Move the operations
switch to lsquoTriprsquo (Rated mA = 100)
g) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200mS
h) Move the selection switch to 0o (-ve wave)
i) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
j) The above test is repeated until a near correct reading is obtained
k) Record the test results
l) Change the operations switch to lsquoFast Triprsquo and press the test button ndash RCD will trip within a
time not exceeding 40 millisecond
m) Repeat a number of times at 0o or 180o
On completion of a wiring installation a number of tests on the installation have to be conducted to
ascertain that the wiring circuits and connected appliances are safe for use Prior to carrying out the
tests an inspection has to be done the following tests shall be conducted
i Continuity Test
ii Insulation Resistance Test
iii Polarity Test
iv Earth Electrode Resistance test and
v Residual Current Device Test
821 Continuity Test
There are 3 main types of continuity tests for the final circuits-
i Protection Conductor Continuity Test
ii Final Ring Circuit Conductor Continuity Test
68 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
iii Live and Neutral Conductor Continuity Test
a) Protection Conductor Continuity Test
bull To ascertain that all protection conductors are connected in the correct and effective manner
bull Test equipment ndash Multimeter (Ohm range) or Ohm meter
bull Test Method
1 1048766 Ensure that the main switch RCD and MCB are open circuited (switched off) and all loads are
disconnected
2 1048766 Connected the test leads as in the Figure 81
3 1048766 The meter reading shall be less than 1 Ω
Final Ring Circuit Conductor Continuity Test
bull To ensure that all conductors around the ring circuit have continuity
bull Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
bull Test Method
1 1048766 Disconnect both the supply source live conductors from the MCB the neutral conductor
from the neutral terminals and the earth conductor from the earth terminal in the distribution
fuse box
2 1048766 Connect the test leads as in the Figure 82 (EE)
3 1048766 Repeat the procedure for (L-L) and (N-N)
4 1048766 The meter reading value shall be less than 1 ohm Figure 82 - Final Ring Circuit Conductor
Continuity Test Ohm Meter
Disconnect both the supply source cables from mcbfuse
Take readings at earth conductors of both sources and note resistance readings
Live and Neutral Conductor Continuity Test
1 To ensure that each conductor in the circuit has continuity
2 Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
3 Test Method
1 1048766 Switch off the Main switch RCD and MCB
2 1048766 Disconnect all loads
3 1048766 Switch on all switches in the circuit
4 1048766 Disconnect the fusesfinal circuit breakers and close the circuit
5 1048766 Carry out the test as shown in Figure 83
6 1048766 The meter reading value shall be less than 1 ohm Figure 83 - Live and Neutral
Conductor Continuity Test Ohm Meter
Insulation Resistance Test
69 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
i Ensure that there is no leakage current between phase conductors phase and neutral conductors and
phase conductor and earth
ii Test the strength of the cable insulation
iii Test Equipment ndash Insulation Resistance Tester Operating voltage is 250VDC or 500VDC
iv Test Method
1 1048766 Switch off main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in the Table below
5 1048766 Meter reading value shall be less than 1 Megaohm
Polarity Test
i Ensure that each fuse or single pole control and protection device is connected only in the phase
conductor
ii Intermediate contact of Edison screw lamp holder is connected to the phase conductor
iii Ensure that phase neutral and earth conductors at socket outlets are connected at the correct
terminals
iv Test Equipment ndash Multimeter (Ohm range) or Ohm meter
v Test Method
1 1048766 Switch off Main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in Figure 85
5 1048766 Test switches and single phase control devices at the phase conductors
6 1048766 Test socket outlet connection sources
7 1048766 Test Edison screw lamp holder connections
8 1048766 Meter reading value shall be less than 1 Ω
Earth Electrode Resistance Test
i To test the earth electrode resistance
70 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
ii To ascertain the suitability of the location of the electrode
iii To ensure that the electrode is not buried within the resistance area of another electrode
iv Test equipment ndash Earth Resistance Tester
v Test method -
1 1048766 Terminal rsquoErsquo is connected to the electrode to be tested (green conductor)
2 1048766 Terminal lsquoPrsquo is connected to the potential spike (yellow conductor) at a distance of 10
meters from the earth electrode
3 1048766 Terminal lsquoCrsquo is connected to the current spike (red conductor) at a distance of 20 meters
from the earth electrode E P C Electrode 10 meter 10 meter
Figure 86 ndash Earth Electrode Resistance Measurement Test Equipment
Earth Electrode Resistance Measurement Method (Figure 86)
This test must be repeated at least three times to ensure that the reading is not affected by interacting
earthing regions
i Record the first reading (Z1) Example Z1 = 10 Ω
ii Move the voltage spike to a distance of 6 meters from the original position Record the second
reading (Z2) Example Z2 = 10 Ω
iii Move the voltage spike to a distance of 6 meters from the original position Record the third
reading (Z3)
Example Z3 = 10 Ω
Residual Current Device Test
71 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
i Ensure that the residual current device (RCD) trips within the set time on the occurrence of current
leakage to earth
ii Test Equipment ndash RCD Tester RCCB Tester
iii Test Method 1
1 1048766 Use the Trip Test Button
2 1048766 Press the trip button found on the RCD to determine if it trips or otherwise This test would
not be able to determine the sensitivity of the RCD nor the time taken for it to trip
iv Test Method 2
1048766 Use a RCD Tester
This equipment is equipped with a 13A plug which can be connected to a 13A socket outlet Select the
RCD sensitivity to be the same as the sensitivity of the RCD to be tested to determine if the RCD can
trip The time to trip shall not exceed 40 mS
1048766 Test method ndash
a) Position the selection switch in accordance with the sensitivity of the RCD used
Example 100 mA 01 A
b) Position the operations switch to lsquoNo Triprsquo (frac12 Rated mA = 50) connect the 3 pin plug to
the 13A socket outlet
c) Switch on the 13A socket outlet ndash ensure that the P-N and P-E lights light up This shows that
the polarity is correct (Note if both the lights as above do not light up the test cannot be
continued)
d) Press the test button ndash the reading shows less than 200 millisecond and simultaneously the
lsquotestrsquo light lights up and the P-N and P-E lights do not light up At that instant the RCD will
not trip
e) Move the selection switch to 180o (+ve wave) ndash repeat steps (d) and (e) = 100)
f) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
g) Move the selection switch to 0o (-ve wave)
h) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
i) The above test is repeated until a near correct reading is obtained
j) Record the test results
k) Change the operations switch to lsquoFast Triprsquo and press the test button ndash RCD will trip within a
time not exceeding 40 mS
l) Repeat a number of times at 0o or 180o
72 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 9 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (DC)
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
73 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Start stop button 240Vac 5A 2
9 Filament lamp (Bulb ) 240Vac 40W 3
10 Overload Relay 415V 20A 3
11 Three phase induction motor 5 hp 3
12 Single phase step down transformer 2500VA 1
13 Single core PVC insulated Cable 1mm 2 As required
14 Single core PVC insulated Cable 25mm 2 As required
15 DIN rail 35 mm As required
16 PVC type Cable tray 50 mm x 50 mm As required
17 Cable ties 4 ldquo As required
18 Flexible wires 05 mm As required
19 PVC Connectors 5 A amp 20 A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the schematic
diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a optional exercise
i Simple DOL starter
ii Forward reverse DOL starter
iii Forward Reverse Dahlander motor
iv Three motors operated in sequence by DOL starter operated by manual push
button or time delay relay
74 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
a One loop per-cycle
b Continuous operation in a loop
c optional circuit design to represent the same task
v Only one out of three motors to be operated at a time (quiz)
4 Test the functionality of completed project
LESSON 10 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (AC)
75 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 1
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Lamp point 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
76 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
11 Overload Relay 415V 20A 3
12 Three phase induction
motor
5 hp 3
13 Single core PVC insulated
Cable
1mm 2 As required
14 Single core PVC insulated
Cable
25mm 2 As required
15 DIN rail 35 mm As required
16 PVC type Cable tray 50 mm x 50 mm As required
17 Cable ties 4 ldquo As required
18 Flexible wires 05 mm As required
19 PVC Connectors 5 A amp 20 A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the
schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram optional exercise
4 Simple DOL starter
5 Forward reverse DOL starter
6 Test the functionality of completed project
77 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 1
78 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
cm
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Indicating light 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
11 Overload Relay 415V 20A 3
12 Three phase induction motor 5 hp 3
13 Single phase step down
transformer
2500VA 1
14 Single core PVC insulated
Cable
1mm 2 As required
15 Single core PVC insulated
Cable
25mm 2 As required
16 DIN rail 35 mm As required
17 PVC type Cable tray 50 mm x 50 mm As required
18 Cable ties 4 ldquo As required
19 Flexible wires 05 mm As required
20 PVC Connectors 5 A amp 20 A 240 V As required
21 Single pole MCB 6A 240 V 1
22 Single pole MCB 2A 240 V 1
23 Triple pole MCB 20A 415 V 1
24 Mounting board 30 cm x 40 cm x 3
cm
1
25 Relay cw 11 pin socket 10 A 240 Vac 2
26 Time delay relay 10 A 240 Vac 3
27 Triple pole Contactor 20A 240Vac 3
28 Batten type Lamp holder 240Vac 10 A 3
29 Start stop button 240Vac 10A 2
30 Indicating light (Bulb ) 240Vac 25W 3
31 Overload Relay 415V 20A 1
32 Three phase dahlander type
induction motor
5 hp 1
33 Single phase step down
transformer
24024Vac
2500VA
1
79 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
34 Single core PVC insulated
Cable
1mm 2 As required
35 Single core PVC insulated
Cable
25mm 2 As required
36 DIN rail 35 mm As required
37 PVC type Cable tray 50 mm x 50 mm As required
38 Cable ties 4 ldquo As required
39 Flexible wires 075 mm As required
40 PVC Connectors 5 A amp 20 A 240 V As required
41 Terminal block 20A 240Vac As required
Procedures
5 Identify each component according to specification and quantity required from the schematic
diagram attached
6 Test the functionality of each component by using multi-meter or power supply whichever
applicable
7 Wire component according to circuit diagram
8 Three motors operated in sequence by DOL starter operated by manual push button or time
delay relay
a One loop per-cycle
b Continuous operation in a loop
c optional circuit design to represent the same task
d Only one out of three motors to be operated at a time (quiz)
9 Test the functionality of completed project
80 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
BASIC DESIGN INDUSTRIAL MOTOR CONTROL (SEQUENCE CONTROL)
THREE PHASE INDUCTION MOTOR OPERATED IN SEQUENCE BY DIRECT ON LINE
STARTER
LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
81 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
82 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Lcd lamp indicator 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
11 Overload Relay 415V 20A 3
12 Three phase induction motor 5 hp 3
13 Single phase step down transformer 2500VA 1
14 Single core PVC insulated Cable 1mm 2 As required
15 Single core PVC insulated Cable 25mm 2 As required
16 DIN rail 35 mm As required
17 PVC type Cable tray 50 mm x 50 mm As required
18 Cable ties 4 ldquo As required
19 Flexible wires 1 mm Oslash As required
20 PVC Terminal block 10A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the schematic
diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a optional exercise
i Forward Reverse dahlander motor
4 Test the functionality of completed project
83 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
THREE PHASE DAHLANDER TYPE INDUCTION MOTOR OPERATED FORWARD AND
REVERSE OPERATION BY DIRECT ON LINE STARTER
84 ndash 99EASYTECH ENTERPRISE
LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
Introduction
If a motors windings are connected in the star configuration any two phases will be in series across
the supply and hence the line current will be smaller(by 577) than if the windings were connected in
the delta arrangement
Hence larger-type motors with heavy starting currents are first connected in star and then when the
starting currents fall in delta This of course means that all six of the ends of the windings must be
brought to terminations outside the casing (Fig 833)
EZTECH
EZTECH ELECTRICAL INSTALLATION GUIDE
The automatic version of this starter incorporates a timing relay which automatically changes the
connections from star to delta Figs 834 and 835 show the wiring and schematic diagrams for a star
delta starter
Objectives
1 Identify component and the specification
2 Design forward reverse star delta starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
2 ndash 99EASYTECH ENTERPRISE
REV -C
LEGENDMCCB Moulded Case Circuit BreakerTOR Thermal Over Load RelayFOW-C Mains Forward ContactorREV-C Mains Reverse ContactorDC Delta ContactorSC Star ContactorS-SW Mains Selector Switch
SC
V2
W2
U2
DC
V1
W1
U1
TOR
TOR
FOW-C
30A MCCB
TOR
MAIN CIRCUIT FORWARD REVERSE STAR DELTA
RYBN S
-SW
3 PHASEINDUCTION MOTOR
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Relay 10 A 240V 3
5 Triple pole Contactor
6 cw NO NC auxiliary contact
240Vac 20 A 4
7 Overload Relay 415 V 1
8 LED indicator 240vac 5 A 4
9 Start stop button 240Vac 5A 2
10 DIN rail 35 mm As required
11 Flexible wires 1 mm As required
12 Single core PVC insulated
wire
25 mm As required
13 Terminal block 20 A As required
14 Squirrel cage motor 5kW 1
15 5 pin plug and socket 415V 20A 1
16 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
3 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
a Manual star delta
b Manual Forward reverse star delta starter
c Automatic star delta starter
d Automatic Forward reverse star delta starter
4 Test the functionality of completed project
4 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
Objectives
1 Identify component and the specification
2 Design auto transformer starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
5 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Autotransformer starter is used to start a 3 phase induction motor that has a rating between 10 to 15 hp
6 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Autotransformer set 10Kw 415 V 50 Hz 1
5 Triple pole Contactor 240Vac 4
6 Batten type Lamp holder 240 Vac 105 A 4
7 Start stop button 240Vac 10A 4
8 Filament lamp (Bulb ) 240Vac 40W 4
9 DIN rail 35 mm As required
10 Flexible wires 1 mm As required
7 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
11 Single core PVC insulated
wire
25 mm As required
12 Terminal block 20 A As required
13 Squirrel cage motor 10kW 1
14 5 pin plug and socket 415V 20A 1
15 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a open transient autotransformer starter
b close transient autotransformer starter
c Forward reverse autotransformer starter
4 Test the functionality of completed project
8 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
Objectives
1 Identify component and the specification
2 Design rotor resistance starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
9 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Rotor Resistor set 10kW 1
5 Triple pole Contactor 240Vac 20A 4
6 Indicating light 240vac 5 A 4
7 Start stop push button 240Vac 5A 4
8 DIN rail 35 mm As required
9 Flexible wires 1 mm 2 As required
10 Single core PVC insulated wire 25 mm 2 As required
11 Terminal block 20 A As required
12 Slip Ring motor 10kW 1
13 5 pin round 3 phase socket 415V 20A 1
14 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
10 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
4 Test the functionality of completed project
a Dead circuit test b Life circuit test
5 Measure starting and running Amps
LESSON 16
TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
An installation in general will suffer damage
Damage usually occurs on the electric motor control as follows
1 Damage to the main circuit
2 Damage to the control circuit
The cause of the damage
i Overcurrent overload short circuit
ii Leakage current to ground
iii Equipment malfunction
iv The main control circuit
a Trip of main circuit protection devices fire
b Defect of motor terminal such as short circuit fire loose
v The control circuit is not functioning -
a contactor relay relay time overload relay does not work damaged burned
b Loose cable connection disconnected
Detecting and Repairing Damage
Examples of damage are as follows
i Motor does not work
ii Motor function and overload relay trips
iii Motor function but only partially functional control circuit
Methods of detecting damage
Among the known methods necessary to detect damage are as follows
1 Turn off the electricity at the main switch (main switch) in order to avoid any danger during the
work carried out to detect damage
2 Check all the protective gear that controls the motor control main circuit
11 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
3 Make sure the damage function control circuit
4 Check the control circuit according to the schematic circuit diagram of the motor control
5 Check the operation of the control circuit
Note
Use wiring that has been installed on the SYSTEM OF MOTOR CONTROL BOARD by Forward
Reverse control circuit for Star Delta to test and look for damage
SELF-ASSESSMENT QUESTIONS
1 (a) Explain what is meant by the term lsquoback emfrsquo in a motor
(b) Outline the basic differences between series shunt and compound wound dc motors
2 (a) With the aid of diagrams explain how the speed of series shunt and compound-wound motors
may be controlled
(b) A 440V dc shunt-wound motor has a field resistance of 200R and an armature resistance of 06 R
When its speed is 20 rev d second the current drawn from the supply is 122A Calculate its back
emf at this speed If the speed were decreased to 19 revssecond the field flux remaining unchanged
calculate the new back emf and the new armature current
3 A load of 64 kW at 240 V is supplied from the terminals of a shunt-wound dc generator The field
resistance is 180 A Calculate the armature current
4 (a) Explain with the aid of a diagram how a rotating magnetic field may be
(b) What is meant by lsquosynchronous speedrsquo
Calculate the synchronous obtained speed of a 12 pole motor if the supply frequency is 50Hz
5 (a) Explain the action of a synchronous motor
(b) What methods are available to start a synchronous motor Explain with diagrams
6 (a) Explain the action of a cage induction motor
(b) What is meant by the term lsquosliprsquo
Calculate the percentage slip of a six pole induction motor running at 162 revssecond from a 50 Hz
supply
7 Describe with sketches three different ways of starting a single-phase induction motor
12 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
8 Explain with the aid of a sketch the action of a three-phase DOL starter
What are dashpots used for How are remote start and stop buttons connected
9 A I0 kW 240V 50Hz single-phase cage rotor induction motor is 85efficient and has a PF of 068
lagging Calculate the motor current and the value of capacitor required to raise the PF to 093
lagging
10 Calculate the torque developed by an 18 kW four-pole induction motor run at 35 slip from a
50Hz supply
APPENDIX 1
13 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 11
14 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 111
Attachment Reference
httpswwwtlc-directcoukBook621htm
httpwwwstgovmyindexphpms
15 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
46 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
47 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
48 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify each component and the specification
2 Wire component according to the schematic diagram given
3 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting Board 450 x 600 mm Perforated metal 1
2 5 pin round socket and plug 415V ac 32A 1
3 Cut out fuse 60 A 3
4 Neutral link 1
5 kWatt hour meter 415V 60A 1
6 ELCB RCCB 3P+N In=63A415 Vac I trip= 300mA 1
7 ELCB RCCB 3P+N In=63A415 Vac I trip= 30mA 1
8 Single pole MCB 6A 240 V 3
9 Single pole MCB 20A 240 V 3
10 DOL starter 20 A 240Vac 2
11 Socket outlet 15 A 240 Vac 1
12 Switched Socket outlet 13 A 240 Vac 3
13 Led indicating light 5A 240 Vac 3
14 Single pole 4 gang 1 way switch 5A 240 Vac 2
15 Single pole 2 way switch 5A 240 Vac 2
16 1 phase induction motor 1 kW 240Vac 1
17 Metal trunking 30 mm x30 mm As required
18 Self tapping Wood screw 4 mm x 20 mm As required
19 DIN rail 25 mm x 1mm
20 GI steel rigid conduit 20mm As required
21 Flexible conduit 20mm As required
22 End box 20 mm 4
23 Flexible wires 05 mm 2 As required
24 Single core PVC insulated wire 15 mm 2 As required
25 Single core PVC insulated wires 25 mm 2 As required
26 Terminal block 10 A As required
Procedures
49 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify each components and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
4 Test the functionality of completed project
1 dead circuit test
2 life circuit
Note Proper earthing should be made
50 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 7 ndash WIRING SYSTEM OF THREE PHASE LIGHTING AND POWER CIRCUIT
51 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
52 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify component and the specification
2 Wire component according to the schematic diagram
3 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting bay Board Perforated metal 180 cm x 180 cm 1
2 k Watt hour meter 415V 60A 1
3 MCCB 415V 60A
4 ELCB RCCB In=60A415 Vac I trip=30mA 1
5 5 pin round Socket and
plug
415Vac 32A 4
6 Single pole MCB 6A 1
7 Triple pole MCB 20A 2
8 Triple pole Main switch 60A 1
9 DOL starter 240Vac 2
10 3 phase induction motor 2hp 415 Vac 1
11 1 phase induction motor 1
12 Metal trunking 30 mm x30 mm As required
13 Self tapping Wood screw 4 mm x 20 mm As required
14 DIN rail 25 mm x 1mm
15 GI steel rigid conduit 20mm As required
16 Flexible conduit 20mm As required
17 End box 20 mm 4
18 Flexible wires 05 mm As required
19 Connectors 10 A As required
Procedures
1 Identify each components and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
4 Test the functionality of completed project
1 dead circuit 2 life circuit test
5 Record the current drawn by the load as connected in star and delta
Note Proper earthing should be made
53 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 8 INSPECTION AND TESTING OF ELECTRICAL INSTALLATION
On completion of a wiring installation a number of tests on the installation have to be conducted to
ascertain that the wiring circuits and connected appliances are safe for use Prior to carrying out the
tests an inspection has to be done The results of the inspectionsupervision and test have to be
presented in Form G (as in Appendix IV) and Form H (as in Appendix V)
To have the test certification as in Form H the following tests shall be conducted
i Continuity Test
ii Insulation Resistance Test
iii Polarity Test
iv Earth Electrode Resistance test and
v Residual Current Device Test
1 Continuity Test
There are 3 main types of continuity tests for the final circuits-
i Protection Conductor Continuity Test
ii Final Ring Circuit Conductor Continuity Test
iii Live and Neutral Conductor Continuity Test
a) Protection Conductor Continuity Test
bull To ascertain that all protection conductors are connected in the correct and effective manner
bull Test equipment ndash Multimeter (Ohm range) or Ohm meter
54 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
bull Test Method
1 1048766 Ensure that the main switch RCD and MCB are open circuited (switched off) and all loads
are disconnected
2 1048766 Connected the test leads as in the Figure 81 The meter reading shall be less than 1 Ω
55 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Final Ring Circuit Conductor Continuity Test
bull To ensure that all conductors around the ring circuit have continuity
bull Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
bull Test Method
1 1048766 Disconnect both the supply source live conductors from the MCB the neutral conductor
from the neutral terminals and the earth conductor from the earth terminal in the distribution
fuse box
2 1048766 Connect the test leads as in the Figure 82 (EE)
3 1048766 Repeat the procedure for (L-L) and (N-N)
4 1048766 The meter reading value shall be less than 1 ohm
56 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Live and Neutral Conductor Continuity Test
a To ensure that each conductor in the circuit has continuity
b Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
2 Test Method
1 1048766 Switch off the Main switch RCD and MCB
2 1048766 Disconnect all loads
3 1048766 Switch on all switches in the circuit
4 1048766 Disconnect the fusesfinal circuit breakers and close the circuit
5 1048766 Carry out the test as shown in Figure 83
6 1048766 The meter reading value shall be less than 1Ω
57 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
58 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
CONTINUITY TEST
Insulation Resistance Test
i Ensure that there is no leakage current between phase conductors phase and neutral conductors and
phase conductor and earth
ii Test the strength of the cable insulation
iii Test Equipment ndash Insulation Resistance Tester operating voltage is 250VDC or 500VDC
iv Test Method
1 1048766 Switch off main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
59 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
4 1048766 Carry out test as in the Table below
5 1048766 Meter reading value shall be less than 1 Megaohm
60 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
61 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Insulation resitance test
62 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
INSULATION RESISTANCE TEST BETWEEN CONDUCTORS AND OPPOSITE POLARITY
Polarity Testi Ensure that each fuse or single pole control and protection device is connected only in the phase
conductor
ii Intermediate contact of Edison screw lamp holder is connected to the phase conductor
iii Ensure that phase neutral and earth conductors at socket outlets are connected at the correct
terminals
iv Test Equipment ndash Multimeter (Ohm range) or Ohm meter
v Test Method
1 1048766 Switch off Main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in Figure 85
63 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
5 1048766 Test switches and single phase control devices at the phase conductors
6 1048766 Test socket outlet connection sources
7 1048766 Test Edison screw lamp holder connections
8 1048766 Meter reading value shall be less than 1 Ω
64 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Polarity test
65 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Earth Electrode Resistance Testi To test the earth electrode resistance
ii To ascertain the suitability of the location of the electrode
iii To ensure that the electrode is not buried within the resistance area of another electrode
iv Test equipment ndash Earth Resistance Tester
v Test method -
1 1048766 Terminal rsquoErsquo is connected to the electrode to be tested (green conductor)
2 1048766 Terminal lsquoPrsquo is connected to the potential spike (yellow conductor) at a distance of 10
meters from the earth electrode
3 1048766 Terminal lsquoCrsquo is connected to the current spike (red conductor) at a distance of 20 meters
from the earth electrode
Earth Electrode Resistance Measurement Method (Figure 86)
This test must be repeated at least three times to ensure that the reading is not affected by interacting
earthing regions
i Record the first reading (Z1) Example Z1 = 10 Ω
ii Move the voltage spike to a distance of 6 meters from the original position Record the second
reading (Z2 ) Example Z2 = 10 Ω
iii Move the voltage spike to a distance of 6 meters from the original position Record the third
reading (Z3) Example Z3 = 10 Ω
66 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Residual Current Device Testi Ensure that the residual current device (RCD) trips within the set time on the occurrence of current
leakage to earth
ii Test Equipment ndash RCD Tester RCCB Tester
iii Test Method 1
1 1048766 Use the Trip Test Button
2 1048766 Press the trip button found on the RCD to determine if it trips or otherwise This test would
not be able to determine the sensitivity of the RCD nor the time taken for it to trip
iv Test Method 2
i 1048766 Use a RCD Tester
ii This equipment is equipped with a 13A plug which can be connected to a 13A socket outlet
Select the RCD sensitivity to be the same as the sensitivity of the RCD to be tested to
determine if the RCD can trip The time to trip shall not exceed 40 mS
iii 1048766 Test method ndash
a) Position the selection switch in accordance with the sensitivity of the RCD used
Example 100 mA 01 A
b) Position the operations switch to lsquoNo Triprsquo (frac12 Rated mA = 50) connect the 3 pin plug to
the 13A socket outlet
67 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
c) Switch on the 13A socket outlet ndash ensure that the P-N and P-E lights light up
This shows that the polarity is correct (Note if both the lights as above do not light up the test cannot
be continued)
d) Press the test button ndash the reading shows less than 200 mS and simultaneously the lsquotestrsquo light lights
up and the P-N and P-E lights do not light up At that instant the RCD will not trip
e) Move the selection switch to 180o (+ve wave) ndash repeat steps (d) and (e) Move the operations
switch to lsquoTriprsquo (Rated mA = 100)
g) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200mS
h) Move the selection switch to 0o (-ve wave)
i) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
j) The above test is repeated until a near correct reading is obtained
k) Record the test results
l) Change the operations switch to lsquoFast Triprsquo and press the test button ndash RCD will trip within a
time not exceeding 40 millisecond
m) Repeat a number of times at 0o or 180o
On completion of a wiring installation a number of tests on the installation have to be conducted to
ascertain that the wiring circuits and connected appliances are safe for use Prior to carrying out the
tests an inspection has to be done the following tests shall be conducted
i Continuity Test
ii Insulation Resistance Test
iii Polarity Test
iv Earth Electrode Resistance test and
v Residual Current Device Test
821 Continuity Test
There are 3 main types of continuity tests for the final circuits-
i Protection Conductor Continuity Test
ii Final Ring Circuit Conductor Continuity Test
68 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
iii Live and Neutral Conductor Continuity Test
a) Protection Conductor Continuity Test
bull To ascertain that all protection conductors are connected in the correct and effective manner
bull Test equipment ndash Multimeter (Ohm range) or Ohm meter
bull Test Method
1 1048766 Ensure that the main switch RCD and MCB are open circuited (switched off) and all loads are
disconnected
2 1048766 Connected the test leads as in the Figure 81
3 1048766 The meter reading shall be less than 1 Ω
Final Ring Circuit Conductor Continuity Test
bull To ensure that all conductors around the ring circuit have continuity
bull Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
bull Test Method
1 1048766 Disconnect both the supply source live conductors from the MCB the neutral conductor
from the neutral terminals and the earth conductor from the earth terminal in the distribution
fuse box
2 1048766 Connect the test leads as in the Figure 82 (EE)
3 1048766 Repeat the procedure for (L-L) and (N-N)
4 1048766 The meter reading value shall be less than 1 ohm Figure 82 - Final Ring Circuit Conductor
Continuity Test Ohm Meter
Disconnect both the supply source cables from mcbfuse
Take readings at earth conductors of both sources and note resistance readings
Live and Neutral Conductor Continuity Test
1 To ensure that each conductor in the circuit has continuity
2 Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
3 Test Method
1 1048766 Switch off the Main switch RCD and MCB
2 1048766 Disconnect all loads
3 1048766 Switch on all switches in the circuit
4 1048766 Disconnect the fusesfinal circuit breakers and close the circuit
5 1048766 Carry out the test as shown in Figure 83
6 1048766 The meter reading value shall be less than 1 ohm Figure 83 - Live and Neutral
Conductor Continuity Test Ohm Meter
Insulation Resistance Test
69 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
i Ensure that there is no leakage current between phase conductors phase and neutral conductors and
phase conductor and earth
ii Test the strength of the cable insulation
iii Test Equipment ndash Insulation Resistance Tester Operating voltage is 250VDC or 500VDC
iv Test Method
1 1048766 Switch off main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in the Table below
5 1048766 Meter reading value shall be less than 1 Megaohm
Polarity Test
i Ensure that each fuse or single pole control and protection device is connected only in the phase
conductor
ii Intermediate contact of Edison screw lamp holder is connected to the phase conductor
iii Ensure that phase neutral and earth conductors at socket outlets are connected at the correct
terminals
iv Test Equipment ndash Multimeter (Ohm range) or Ohm meter
v Test Method
1 1048766 Switch off Main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in Figure 85
5 1048766 Test switches and single phase control devices at the phase conductors
6 1048766 Test socket outlet connection sources
7 1048766 Test Edison screw lamp holder connections
8 1048766 Meter reading value shall be less than 1 Ω
Earth Electrode Resistance Test
i To test the earth electrode resistance
70 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
ii To ascertain the suitability of the location of the electrode
iii To ensure that the electrode is not buried within the resistance area of another electrode
iv Test equipment ndash Earth Resistance Tester
v Test method -
1 1048766 Terminal rsquoErsquo is connected to the electrode to be tested (green conductor)
2 1048766 Terminal lsquoPrsquo is connected to the potential spike (yellow conductor) at a distance of 10
meters from the earth electrode
3 1048766 Terminal lsquoCrsquo is connected to the current spike (red conductor) at a distance of 20 meters
from the earth electrode E P C Electrode 10 meter 10 meter
Figure 86 ndash Earth Electrode Resistance Measurement Test Equipment
Earth Electrode Resistance Measurement Method (Figure 86)
This test must be repeated at least three times to ensure that the reading is not affected by interacting
earthing regions
i Record the first reading (Z1) Example Z1 = 10 Ω
ii Move the voltage spike to a distance of 6 meters from the original position Record the second
reading (Z2) Example Z2 = 10 Ω
iii Move the voltage spike to a distance of 6 meters from the original position Record the third
reading (Z3)
Example Z3 = 10 Ω
Residual Current Device Test
71 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
i Ensure that the residual current device (RCD) trips within the set time on the occurrence of current
leakage to earth
ii Test Equipment ndash RCD Tester RCCB Tester
iii Test Method 1
1 1048766 Use the Trip Test Button
2 1048766 Press the trip button found on the RCD to determine if it trips or otherwise This test would
not be able to determine the sensitivity of the RCD nor the time taken for it to trip
iv Test Method 2
1048766 Use a RCD Tester
This equipment is equipped with a 13A plug which can be connected to a 13A socket outlet Select the
RCD sensitivity to be the same as the sensitivity of the RCD to be tested to determine if the RCD can
trip The time to trip shall not exceed 40 mS
1048766 Test method ndash
a) Position the selection switch in accordance with the sensitivity of the RCD used
Example 100 mA 01 A
b) Position the operations switch to lsquoNo Triprsquo (frac12 Rated mA = 50) connect the 3 pin plug to
the 13A socket outlet
c) Switch on the 13A socket outlet ndash ensure that the P-N and P-E lights light up This shows that
the polarity is correct (Note if both the lights as above do not light up the test cannot be
continued)
d) Press the test button ndash the reading shows less than 200 millisecond and simultaneously the
lsquotestrsquo light lights up and the P-N and P-E lights do not light up At that instant the RCD will
not trip
e) Move the selection switch to 180o (+ve wave) ndash repeat steps (d) and (e) = 100)
f) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
g) Move the selection switch to 0o (-ve wave)
h) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
i) The above test is repeated until a near correct reading is obtained
j) Record the test results
k) Change the operations switch to lsquoFast Triprsquo and press the test button ndash RCD will trip within a
time not exceeding 40 mS
l) Repeat a number of times at 0o or 180o
72 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 9 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (DC)
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
73 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Start stop button 240Vac 5A 2
9 Filament lamp (Bulb ) 240Vac 40W 3
10 Overload Relay 415V 20A 3
11 Three phase induction motor 5 hp 3
12 Single phase step down transformer 2500VA 1
13 Single core PVC insulated Cable 1mm 2 As required
14 Single core PVC insulated Cable 25mm 2 As required
15 DIN rail 35 mm As required
16 PVC type Cable tray 50 mm x 50 mm As required
17 Cable ties 4 ldquo As required
18 Flexible wires 05 mm As required
19 PVC Connectors 5 A amp 20 A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the schematic
diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a optional exercise
i Simple DOL starter
ii Forward reverse DOL starter
iii Forward Reverse Dahlander motor
iv Three motors operated in sequence by DOL starter operated by manual push
button or time delay relay
74 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
a One loop per-cycle
b Continuous operation in a loop
c optional circuit design to represent the same task
v Only one out of three motors to be operated at a time (quiz)
4 Test the functionality of completed project
LESSON 10 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (AC)
75 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 1
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Lamp point 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
76 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
11 Overload Relay 415V 20A 3
12 Three phase induction
motor
5 hp 3
13 Single core PVC insulated
Cable
1mm 2 As required
14 Single core PVC insulated
Cable
25mm 2 As required
15 DIN rail 35 mm As required
16 PVC type Cable tray 50 mm x 50 mm As required
17 Cable ties 4 ldquo As required
18 Flexible wires 05 mm As required
19 PVC Connectors 5 A amp 20 A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the
schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram optional exercise
4 Simple DOL starter
5 Forward reverse DOL starter
6 Test the functionality of completed project
77 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 1
78 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
cm
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Indicating light 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
11 Overload Relay 415V 20A 3
12 Three phase induction motor 5 hp 3
13 Single phase step down
transformer
2500VA 1
14 Single core PVC insulated
Cable
1mm 2 As required
15 Single core PVC insulated
Cable
25mm 2 As required
16 DIN rail 35 mm As required
17 PVC type Cable tray 50 mm x 50 mm As required
18 Cable ties 4 ldquo As required
19 Flexible wires 05 mm As required
20 PVC Connectors 5 A amp 20 A 240 V As required
21 Single pole MCB 6A 240 V 1
22 Single pole MCB 2A 240 V 1
23 Triple pole MCB 20A 415 V 1
24 Mounting board 30 cm x 40 cm x 3
cm
1
25 Relay cw 11 pin socket 10 A 240 Vac 2
26 Time delay relay 10 A 240 Vac 3
27 Triple pole Contactor 20A 240Vac 3
28 Batten type Lamp holder 240Vac 10 A 3
29 Start stop button 240Vac 10A 2
30 Indicating light (Bulb ) 240Vac 25W 3
31 Overload Relay 415V 20A 1
32 Three phase dahlander type
induction motor
5 hp 1
33 Single phase step down
transformer
24024Vac
2500VA
1
79 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
34 Single core PVC insulated
Cable
1mm 2 As required
35 Single core PVC insulated
Cable
25mm 2 As required
36 DIN rail 35 mm As required
37 PVC type Cable tray 50 mm x 50 mm As required
38 Cable ties 4 ldquo As required
39 Flexible wires 075 mm As required
40 PVC Connectors 5 A amp 20 A 240 V As required
41 Terminal block 20A 240Vac As required
Procedures
5 Identify each component according to specification and quantity required from the schematic
diagram attached
6 Test the functionality of each component by using multi-meter or power supply whichever
applicable
7 Wire component according to circuit diagram
8 Three motors operated in sequence by DOL starter operated by manual push button or time
delay relay
a One loop per-cycle
b Continuous operation in a loop
c optional circuit design to represent the same task
d Only one out of three motors to be operated at a time (quiz)
9 Test the functionality of completed project
80 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
BASIC DESIGN INDUSTRIAL MOTOR CONTROL (SEQUENCE CONTROL)
THREE PHASE INDUCTION MOTOR OPERATED IN SEQUENCE BY DIRECT ON LINE
STARTER
LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
81 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
82 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Lcd lamp indicator 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
11 Overload Relay 415V 20A 3
12 Three phase induction motor 5 hp 3
13 Single phase step down transformer 2500VA 1
14 Single core PVC insulated Cable 1mm 2 As required
15 Single core PVC insulated Cable 25mm 2 As required
16 DIN rail 35 mm As required
17 PVC type Cable tray 50 mm x 50 mm As required
18 Cable ties 4 ldquo As required
19 Flexible wires 1 mm Oslash As required
20 PVC Terminal block 10A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the schematic
diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a optional exercise
i Forward Reverse dahlander motor
4 Test the functionality of completed project
83 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
THREE PHASE DAHLANDER TYPE INDUCTION MOTOR OPERATED FORWARD AND
REVERSE OPERATION BY DIRECT ON LINE STARTER
84 ndash 99EASYTECH ENTERPRISE
LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
Introduction
If a motors windings are connected in the star configuration any two phases will be in series across
the supply and hence the line current will be smaller(by 577) than if the windings were connected in
the delta arrangement
Hence larger-type motors with heavy starting currents are first connected in star and then when the
starting currents fall in delta This of course means that all six of the ends of the windings must be
brought to terminations outside the casing (Fig 833)
EZTECH
EZTECH ELECTRICAL INSTALLATION GUIDE
The automatic version of this starter incorporates a timing relay which automatically changes the
connections from star to delta Figs 834 and 835 show the wiring and schematic diagrams for a star
delta starter
Objectives
1 Identify component and the specification
2 Design forward reverse star delta starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
2 ndash 99EASYTECH ENTERPRISE
REV -C
LEGENDMCCB Moulded Case Circuit BreakerTOR Thermal Over Load RelayFOW-C Mains Forward ContactorREV-C Mains Reverse ContactorDC Delta ContactorSC Star ContactorS-SW Mains Selector Switch
SC
V2
W2
U2
DC
V1
W1
U1
TOR
TOR
FOW-C
30A MCCB
TOR
MAIN CIRCUIT FORWARD REVERSE STAR DELTA
RYBN S
-SW
3 PHASEINDUCTION MOTOR
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Relay 10 A 240V 3
5 Triple pole Contactor
6 cw NO NC auxiliary contact
240Vac 20 A 4
7 Overload Relay 415 V 1
8 LED indicator 240vac 5 A 4
9 Start stop button 240Vac 5A 2
10 DIN rail 35 mm As required
11 Flexible wires 1 mm As required
12 Single core PVC insulated
wire
25 mm As required
13 Terminal block 20 A As required
14 Squirrel cage motor 5kW 1
15 5 pin plug and socket 415V 20A 1
16 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
3 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
a Manual star delta
b Manual Forward reverse star delta starter
c Automatic star delta starter
d Automatic Forward reverse star delta starter
4 Test the functionality of completed project
4 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
Objectives
1 Identify component and the specification
2 Design auto transformer starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
5 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Autotransformer starter is used to start a 3 phase induction motor that has a rating between 10 to 15 hp
6 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Autotransformer set 10Kw 415 V 50 Hz 1
5 Triple pole Contactor 240Vac 4
6 Batten type Lamp holder 240 Vac 105 A 4
7 Start stop button 240Vac 10A 4
8 Filament lamp (Bulb ) 240Vac 40W 4
9 DIN rail 35 mm As required
10 Flexible wires 1 mm As required
7 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
11 Single core PVC insulated
wire
25 mm As required
12 Terminal block 20 A As required
13 Squirrel cage motor 10kW 1
14 5 pin plug and socket 415V 20A 1
15 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a open transient autotransformer starter
b close transient autotransformer starter
c Forward reverse autotransformer starter
4 Test the functionality of completed project
8 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
Objectives
1 Identify component and the specification
2 Design rotor resistance starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
9 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Rotor Resistor set 10kW 1
5 Triple pole Contactor 240Vac 20A 4
6 Indicating light 240vac 5 A 4
7 Start stop push button 240Vac 5A 4
8 DIN rail 35 mm As required
9 Flexible wires 1 mm 2 As required
10 Single core PVC insulated wire 25 mm 2 As required
11 Terminal block 20 A As required
12 Slip Ring motor 10kW 1
13 5 pin round 3 phase socket 415V 20A 1
14 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
10 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
4 Test the functionality of completed project
a Dead circuit test b Life circuit test
5 Measure starting and running Amps
LESSON 16
TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
An installation in general will suffer damage
Damage usually occurs on the electric motor control as follows
1 Damage to the main circuit
2 Damage to the control circuit
The cause of the damage
i Overcurrent overload short circuit
ii Leakage current to ground
iii Equipment malfunction
iv The main control circuit
a Trip of main circuit protection devices fire
b Defect of motor terminal such as short circuit fire loose
v The control circuit is not functioning -
a contactor relay relay time overload relay does not work damaged burned
b Loose cable connection disconnected
Detecting and Repairing Damage
Examples of damage are as follows
i Motor does not work
ii Motor function and overload relay trips
iii Motor function but only partially functional control circuit
Methods of detecting damage
Among the known methods necessary to detect damage are as follows
1 Turn off the electricity at the main switch (main switch) in order to avoid any danger during the
work carried out to detect damage
2 Check all the protective gear that controls the motor control main circuit
11 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
3 Make sure the damage function control circuit
4 Check the control circuit according to the schematic circuit diagram of the motor control
5 Check the operation of the control circuit
Note
Use wiring that has been installed on the SYSTEM OF MOTOR CONTROL BOARD by Forward
Reverse control circuit for Star Delta to test and look for damage
SELF-ASSESSMENT QUESTIONS
1 (a) Explain what is meant by the term lsquoback emfrsquo in a motor
(b) Outline the basic differences between series shunt and compound wound dc motors
2 (a) With the aid of diagrams explain how the speed of series shunt and compound-wound motors
may be controlled
(b) A 440V dc shunt-wound motor has a field resistance of 200R and an armature resistance of 06 R
When its speed is 20 rev d second the current drawn from the supply is 122A Calculate its back
emf at this speed If the speed were decreased to 19 revssecond the field flux remaining unchanged
calculate the new back emf and the new armature current
3 A load of 64 kW at 240 V is supplied from the terminals of a shunt-wound dc generator The field
resistance is 180 A Calculate the armature current
4 (a) Explain with the aid of a diagram how a rotating magnetic field may be
(b) What is meant by lsquosynchronous speedrsquo
Calculate the synchronous obtained speed of a 12 pole motor if the supply frequency is 50Hz
5 (a) Explain the action of a synchronous motor
(b) What methods are available to start a synchronous motor Explain with diagrams
6 (a) Explain the action of a cage induction motor
(b) What is meant by the term lsquosliprsquo
Calculate the percentage slip of a six pole induction motor running at 162 revssecond from a 50 Hz
supply
7 Describe with sketches three different ways of starting a single-phase induction motor
12 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
8 Explain with the aid of a sketch the action of a three-phase DOL starter
What are dashpots used for How are remote start and stop buttons connected
9 A I0 kW 240V 50Hz single-phase cage rotor induction motor is 85efficient and has a PF of 068
lagging Calculate the motor current and the value of capacitor required to raise the PF to 093
lagging
10 Calculate the torque developed by an 18 kW four-pole induction motor run at 35 slip from a
50Hz supply
APPENDIX 1
13 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 11
14 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 111
Attachment Reference
httpswwwtlc-directcoukBook621htm
httpwwwstgovmyindexphpms
15 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
47 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
48 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify each component and the specification
2 Wire component according to the schematic diagram given
3 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting Board 450 x 600 mm Perforated metal 1
2 5 pin round socket and plug 415V ac 32A 1
3 Cut out fuse 60 A 3
4 Neutral link 1
5 kWatt hour meter 415V 60A 1
6 ELCB RCCB 3P+N In=63A415 Vac I trip= 300mA 1
7 ELCB RCCB 3P+N In=63A415 Vac I trip= 30mA 1
8 Single pole MCB 6A 240 V 3
9 Single pole MCB 20A 240 V 3
10 DOL starter 20 A 240Vac 2
11 Socket outlet 15 A 240 Vac 1
12 Switched Socket outlet 13 A 240 Vac 3
13 Led indicating light 5A 240 Vac 3
14 Single pole 4 gang 1 way switch 5A 240 Vac 2
15 Single pole 2 way switch 5A 240 Vac 2
16 1 phase induction motor 1 kW 240Vac 1
17 Metal trunking 30 mm x30 mm As required
18 Self tapping Wood screw 4 mm x 20 mm As required
19 DIN rail 25 mm x 1mm
20 GI steel rigid conduit 20mm As required
21 Flexible conduit 20mm As required
22 End box 20 mm 4
23 Flexible wires 05 mm 2 As required
24 Single core PVC insulated wire 15 mm 2 As required
25 Single core PVC insulated wires 25 mm 2 As required
26 Terminal block 10 A As required
Procedures
49 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify each components and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
4 Test the functionality of completed project
1 dead circuit test
2 life circuit
Note Proper earthing should be made
50 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 7 ndash WIRING SYSTEM OF THREE PHASE LIGHTING AND POWER CIRCUIT
51 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
52 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify component and the specification
2 Wire component according to the schematic diagram
3 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting bay Board Perforated metal 180 cm x 180 cm 1
2 k Watt hour meter 415V 60A 1
3 MCCB 415V 60A
4 ELCB RCCB In=60A415 Vac I trip=30mA 1
5 5 pin round Socket and
plug
415Vac 32A 4
6 Single pole MCB 6A 1
7 Triple pole MCB 20A 2
8 Triple pole Main switch 60A 1
9 DOL starter 240Vac 2
10 3 phase induction motor 2hp 415 Vac 1
11 1 phase induction motor 1
12 Metal trunking 30 mm x30 mm As required
13 Self tapping Wood screw 4 mm x 20 mm As required
14 DIN rail 25 mm x 1mm
15 GI steel rigid conduit 20mm As required
16 Flexible conduit 20mm As required
17 End box 20 mm 4
18 Flexible wires 05 mm As required
19 Connectors 10 A As required
Procedures
1 Identify each components and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
4 Test the functionality of completed project
1 dead circuit 2 life circuit test
5 Record the current drawn by the load as connected in star and delta
Note Proper earthing should be made
53 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 8 INSPECTION AND TESTING OF ELECTRICAL INSTALLATION
On completion of a wiring installation a number of tests on the installation have to be conducted to
ascertain that the wiring circuits and connected appliances are safe for use Prior to carrying out the
tests an inspection has to be done The results of the inspectionsupervision and test have to be
presented in Form G (as in Appendix IV) and Form H (as in Appendix V)
To have the test certification as in Form H the following tests shall be conducted
i Continuity Test
ii Insulation Resistance Test
iii Polarity Test
iv Earth Electrode Resistance test and
v Residual Current Device Test
1 Continuity Test
There are 3 main types of continuity tests for the final circuits-
i Protection Conductor Continuity Test
ii Final Ring Circuit Conductor Continuity Test
iii Live and Neutral Conductor Continuity Test
a) Protection Conductor Continuity Test
bull To ascertain that all protection conductors are connected in the correct and effective manner
bull Test equipment ndash Multimeter (Ohm range) or Ohm meter
54 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
bull Test Method
1 1048766 Ensure that the main switch RCD and MCB are open circuited (switched off) and all loads
are disconnected
2 1048766 Connected the test leads as in the Figure 81 The meter reading shall be less than 1 Ω
55 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Final Ring Circuit Conductor Continuity Test
bull To ensure that all conductors around the ring circuit have continuity
bull Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
bull Test Method
1 1048766 Disconnect both the supply source live conductors from the MCB the neutral conductor
from the neutral terminals and the earth conductor from the earth terminal in the distribution
fuse box
2 1048766 Connect the test leads as in the Figure 82 (EE)
3 1048766 Repeat the procedure for (L-L) and (N-N)
4 1048766 The meter reading value shall be less than 1 ohm
56 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Live and Neutral Conductor Continuity Test
a To ensure that each conductor in the circuit has continuity
b Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
2 Test Method
1 1048766 Switch off the Main switch RCD and MCB
2 1048766 Disconnect all loads
3 1048766 Switch on all switches in the circuit
4 1048766 Disconnect the fusesfinal circuit breakers and close the circuit
5 1048766 Carry out the test as shown in Figure 83
6 1048766 The meter reading value shall be less than 1Ω
57 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
58 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
CONTINUITY TEST
Insulation Resistance Test
i Ensure that there is no leakage current between phase conductors phase and neutral conductors and
phase conductor and earth
ii Test the strength of the cable insulation
iii Test Equipment ndash Insulation Resistance Tester operating voltage is 250VDC or 500VDC
iv Test Method
1 1048766 Switch off main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
59 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
4 1048766 Carry out test as in the Table below
5 1048766 Meter reading value shall be less than 1 Megaohm
60 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
61 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Insulation resitance test
62 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
INSULATION RESISTANCE TEST BETWEEN CONDUCTORS AND OPPOSITE POLARITY
Polarity Testi Ensure that each fuse or single pole control and protection device is connected only in the phase
conductor
ii Intermediate contact of Edison screw lamp holder is connected to the phase conductor
iii Ensure that phase neutral and earth conductors at socket outlets are connected at the correct
terminals
iv Test Equipment ndash Multimeter (Ohm range) or Ohm meter
v Test Method
1 1048766 Switch off Main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in Figure 85
63 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
5 1048766 Test switches and single phase control devices at the phase conductors
6 1048766 Test socket outlet connection sources
7 1048766 Test Edison screw lamp holder connections
8 1048766 Meter reading value shall be less than 1 Ω
64 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Polarity test
65 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Earth Electrode Resistance Testi To test the earth electrode resistance
ii To ascertain the suitability of the location of the electrode
iii To ensure that the electrode is not buried within the resistance area of another electrode
iv Test equipment ndash Earth Resistance Tester
v Test method -
1 1048766 Terminal rsquoErsquo is connected to the electrode to be tested (green conductor)
2 1048766 Terminal lsquoPrsquo is connected to the potential spike (yellow conductor) at a distance of 10
meters from the earth electrode
3 1048766 Terminal lsquoCrsquo is connected to the current spike (red conductor) at a distance of 20 meters
from the earth electrode
Earth Electrode Resistance Measurement Method (Figure 86)
This test must be repeated at least three times to ensure that the reading is not affected by interacting
earthing regions
i Record the first reading (Z1) Example Z1 = 10 Ω
ii Move the voltage spike to a distance of 6 meters from the original position Record the second
reading (Z2 ) Example Z2 = 10 Ω
iii Move the voltage spike to a distance of 6 meters from the original position Record the third
reading (Z3) Example Z3 = 10 Ω
66 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Residual Current Device Testi Ensure that the residual current device (RCD) trips within the set time on the occurrence of current
leakage to earth
ii Test Equipment ndash RCD Tester RCCB Tester
iii Test Method 1
1 1048766 Use the Trip Test Button
2 1048766 Press the trip button found on the RCD to determine if it trips or otherwise This test would
not be able to determine the sensitivity of the RCD nor the time taken for it to trip
iv Test Method 2
i 1048766 Use a RCD Tester
ii This equipment is equipped with a 13A plug which can be connected to a 13A socket outlet
Select the RCD sensitivity to be the same as the sensitivity of the RCD to be tested to
determine if the RCD can trip The time to trip shall not exceed 40 mS
iii 1048766 Test method ndash
a) Position the selection switch in accordance with the sensitivity of the RCD used
Example 100 mA 01 A
b) Position the operations switch to lsquoNo Triprsquo (frac12 Rated mA = 50) connect the 3 pin plug to
the 13A socket outlet
67 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
c) Switch on the 13A socket outlet ndash ensure that the P-N and P-E lights light up
This shows that the polarity is correct (Note if both the lights as above do not light up the test cannot
be continued)
d) Press the test button ndash the reading shows less than 200 mS and simultaneously the lsquotestrsquo light lights
up and the P-N and P-E lights do not light up At that instant the RCD will not trip
e) Move the selection switch to 180o (+ve wave) ndash repeat steps (d) and (e) Move the operations
switch to lsquoTriprsquo (Rated mA = 100)
g) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200mS
h) Move the selection switch to 0o (-ve wave)
i) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
j) The above test is repeated until a near correct reading is obtained
k) Record the test results
l) Change the operations switch to lsquoFast Triprsquo and press the test button ndash RCD will trip within a
time not exceeding 40 millisecond
m) Repeat a number of times at 0o or 180o
On completion of a wiring installation a number of tests on the installation have to be conducted to
ascertain that the wiring circuits and connected appliances are safe for use Prior to carrying out the
tests an inspection has to be done the following tests shall be conducted
i Continuity Test
ii Insulation Resistance Test
iii Polarity Test
iv Earth Electrode Resistance test and
v Residual Current Device Test
821 Continuity Test
There are 3 main types of continuity tests for the final circuits-
i Protection Conductor Continuity Test
ii Final Ring Circuit Conductor Continuity Test
68 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
iii Live and Neutral Conductor Continuity Test
a) Protection Conductor Continuity Test
bull To ascertain that all protection conductors are connected in the correct and effective manner
bull Test equipment ndash Multimeter (Ohm range) or Ohm meter
bull Test Method
1 1048766 Ensure that the main switch RCD and MCB are open circuited (switched off) and all loads are
disconnected
2 1048766 Connected the test leads as in the Figure 81
3 1048766 The meter reading shall be less than 1 Ω
Final Ring Circuit Conductor Continuity Test
bull To ensure that all conductors around the ring circuit have continuity
bull Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
bull Test Method
1 1048766 Disconnect both the supply source live conductors from the MCB the neutral conductor
from the neutral terminals and the earth conductor from the earth terminal in the distribution
fuse box
2 1048766 Connect the test leads as in the Figure 82 (EE)
3 1048766 Repeat the procedure for (L-L) and (N-N)
4 1048766 The meter reading value shall be less than 1 ohm Figure 82 - Final Ring Circuit Conductor
Continuity Test Ohm Meter
Disconnect both the supply source cables from mcbfuse
Take readings at earth conductors of both sources and note resistance readings
Live and Neutral Conductor Continuity Test
1 To ensure that each conductor in the circuit has continuity
2 Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
3 Test Method
1 1048766 Switch off the Main switch RCD and MCB
2 1048766 Disconnect all loads
3 1048766 Switch on all switches in the circuit
4 1048766 Disconnect the fusesfinal circuit breakers and close the circuit
5 1048766 Carry out the test as shown in Figure 83
6 1048766 The meter reading value shall be less than 1 ohm Figure 83 - Live and Neutral
Conductor Continuity Test Ohm Meter
Insulation Resistance Test
69 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
i Ensure that there is no leakage current between phase conductors phase and neutral conductors and
phase conductor and earth
ii Test the strength of the cable insulation
iii Test Equipment ndash Insulation Resistance Tester Operating voltage is 250VDC or 500VDC
iv Test Method
1 1048766 Switch off main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in the Table below
5 1048766 Meter reading value shall be less than 1 Megaohm
Polarity Test
i Ensure that each fuse or single pole control and protection device is connected only in the phase
conductor
ii Intermediate contact of Edison screw lamp holder is connected to the phase conductor
iii Ensure that phase neutral and earth conductors at socket outlets are connected at the correct
terminals
iv Test Equipment ndash Multimeter (Ohm range) or Ohm meter
v Test Method
1 1048766 Switch off Main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in Figure 85
5 1048766 Test switches and single phase control devices at the phase conductors
6 1048766 Test socket outlet connection sources
7 1048766 Test Edison screw lamp holder connections
8 1048766 Meter reading value shall be less than 1 Ω
Earth Electrode Resistance Test
i To test the earth electrode resistance
70 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
ii To ascertain the suitability of the location of the electrode
iii To ensure that the electrode is not buried within the resistance area of another electrode
iv Test equipment ndash Earth Resistance Tester
v Test method -
1 1048766 Terminal rsquoErsquo is connected to the electrode to be tested (green conductor)
2 1048766 Terminal lsquoPrsquo is connected to the potential spike (yellow conductor) at a distance of 10
meters from the earth electrode
3 1048766 Terminal lsquoCrsquo is connected to the current spike (red conductor) at a distance of 20 meters
from the earth electrode E P C Electrode 10 meter 10 meter
Figure 86 ndash Earth Electrode Resistance Measurement Test Equipment
Earth Electrode Resistance Measurement Method (Figure 86)
This test must be repeated at least three times to ensure that the reading is not affected by interacting
earthing regions
i Record the first reading (Z1) Example Z1 = 10 Ω
ii Move the voltage spike to a distance of 6 meters from the original position Record the second
reading (Z2) Example Z2 = 10 Ω
iii Move the voltage spike to a distance of 6 meters from the original position Record the third
reading (Z3)
Example Z3 = 10 Ω
Residual Current Device Test
71 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
i Ensure that the residual current device (RCD) trips within the set time on the occurrence of current
leakage to earth
ii Test Equipment ndash RCD Tester RCCB Tester
iii Test Method 1
1 1048766 Use the Trip Test Button
2 1048766 Press the trip button found on the RCD to determine if it trips or otherwise This test would
not be able to determine the sensitivity of the RCD nor the time taken for it to trip
iv Test Method 2
1048766 Use a RCD Tester
This equipment is equipped with a 13A plug which can be connected to a 13A socket outlet Select the
RCD sensitivity to be the same as the sensitivity of the RCD to be tested to determine if the RCD can
trip The time to trip shall not exceed 40 mS
1048766 Test method ndash
a) Position the selection switch in accordance with the sensitivity of the RCD used
Example 100 mA 01 A
b) Position the operations switch to lsquoNo Triprsquo (frac12 Rated mA = 50) connect the 3 pin plug to
the 13A socket outlet
c) Switch on the 13A socket outlet ndash ensure that the P-N and P-E lights light up This shows that
the polarity is correct (Note if both the lights as above do not light up the test cannot be
continued)
d) Press the test button ndash the reading shows less than 200 millisecond and simultaneously the
lsquotestrsquo light lights up and the P-N and P-E lights do not light up At that instant the RCD will
not trip
e) Move the selection switch to 180o (+ve wave) ndash repeat steps (d) and (e) = 100)
f) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
g) Move the selection switch to 0o (-ve wave)
h) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
i) The above test is repeated until a near correct reading is obtained
j) Record the test results
k) Change the operations switch to lsquoFast Triprsquo and press the test button ndash RCD will trip within a
time not exceeding 40 mS
l) Repeat a number of times at 0o or 180o
72 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 9 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (DC)
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
73 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Start stop button 240Vac 5A 2
9 Filament lamp (Bulb ) 240Vac 40W 3
10 Overload Relay 415V 20A 3
11 Three phase induction motor 5 hp 3
12 Single phase step down transformer 2500VA 1
13 Single core PVC insulated Cable 1mm 2 As required
14 Single core PVC insulated Cable 25mm 2 As required
15 DIN rail 35 mm As required
16 PVC type Cable tray 50 mm x 50 mm As required
17 Cable ties 4 ldquo As required
18 Flexible wires 05 mm As required
19 PVC Connectors 5 A amp 20 A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the schematic
diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a optional exercise
i Simple DOL starter
ii Forward reverse DOL starter
iii Forward Reverse Dahlander motor
iv Three motors operated in sequence by DOL starter operated by manual push
button or time delay relay
74 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
a One loop per-cycle
b Continuous operation in a loop
c optional circuit design to represent the same task
v Only one out of three motors to be operated at a time (quiz)
4 Test the functionality of completed project
LESSON 10 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (AC)
75 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 1
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Lamp point 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
76 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
11 Overload Relay 415V 20A 3
12 Three phase induction
motor
5 hp 3
13 Single core PVC insulated
Cable
1mm 2 As required
14 Single core PVC insulated
Cable
25mm 2 As required
15 DIN rail 35 mm As required
16 PVC type Cable tray 50 mm x 50 mm As required
17 Cable ties 4 ldquo As required
18 Flexible wires 05 mm As required
19 PVC Connectors 5 A amp 20 A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the
schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram optional exercise
4 Simple DOL starter
5 Forward reverse DOL starter
6 Test the functionality of completed project
77 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 1
78 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
cm
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Indicating light 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
11 Overload Relay 415V 20A 3
12 Three phase induction motor 5 hp 3
13 Single phase step down
transformer
2500VA 1
14 Single core PVC insulated
Cable
1mm 2 As required
15 Single core PVC insulated
Cable
25mm 2 As required
16 DIN rail 35 mm As required
17 PVC type Cable tray 50 mm x 50 mm As required
18 Cable ties 4 ldquo As required
19 Flexible wires 05 mm As required
20 PVC Connectors 5 A amp 20 A 240 V As required
21 Single pole MCB 6A 240 V 1
22 Single pole MCB 2A 240 V 1
23 Triple pole MCB 20A 415 V 1
24 Mounting board 30 cm x 40 cm x 3
cm
1
25 Relay cw 11 pin socket 10 A 240 Vac 2
26 Time delay relay 10 A 240 Vac 3
27 Triple pole Contactor 20A 240Vac 3
28 Batten type Lamp holder 240Vac 10 A 3
29 Start stop button 240Vac 10A 2
30 Indicating light (Bulb ) 240Vac 25W 3
31 Overload Relay 415V 20A 1
32 Three phase dahlander type
induction motor
5 hp 1
33 Single phase step down
transformer
24024Vac
2500VA
1
79 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
34 Single core PVC insulated
Cable
1mm 2 As required
35 Single core PVC insulated
Cable
25mm 2 As required
36 DIN rail 35 mm As required
37 PVC type Cable tray 50 mm x 50 mm As required
38 Cable ties 4 ldquo As required
39 Flexible wires 075 mm As required
40 PVC Connectors 5 A amp 20 A 240 V As required
41 Terminal block 20A 240Vac As required
Procedures
5 Identify each component according to specification and quantity required from the schematic
diagram attached
6 Test the functionality of each component by using multi-meter or power supply whichever
applicable
7 Wire component according to circuit diagram
8 Three motors operated in sequence by DOL starter operated by manual push button or time
delay relay
a One loop per-cycle
b Continuous operation in a loop
c optional circuit design to represent the same task
d Only one out of three motors to be operated at a time (quiz)
9 Test the functionality of completed project
80 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
BASIC DESIGN INDUSTRIAL MOTOR CONTROL (SEQUENCE CONTROL)
THREE PHASE INDUCTION MOTOR OPERATED IN SEQUENCE BY DIRECT ON LINE
STARTER
LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
81 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
82 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Lcd lamp indicator 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
11 Overload Relay 415V 20A 3
12 Three phase induction motor 5 hp 3
13 Single phase step down transformer 2500VA 1
14 Single core PVC insulated Cable 1mm 2 As required
15 Single core PVC insulated Cable 25mm 2 As required
16 DIN rail 35 mm As required
17 PVC type Cable tray 50 mm x 50 mm As required
18 Cable ties 4 ldquo As required
19 Flexible wires 1 mm Oslash As required
20 PVC Terminal block 10A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the schematic
diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a optional exercise
i Forward Reverse dahlander motor
4 Test the functionality of completed project
83 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
THREE PHASE DAHLANDER TYPE INDUCTION MOTOR OPERATED FORWARD AND
REVERSE OPERATION BY DIRECT ON LINE STARTER
84 ndash 99EASYTECH ENTERPRISE
LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
Introduction
If a motors windings are connected in the star configuration any two phases will be in series across
the supply and hence the line current will be smaller(by 577) than if the windings were connected in
the delta arrangement
Hence larger-type motors with heavy starting currents are first connected in star and then when the
starting currents fall in delta This of course means that all six of the ends of the windings must be
brought to terminations outside the casing (Fig 833)
EZTECH
EZTECH ELECTRICAL INSTALLATION GUIDE
The automatic version of this starter incorporates a timing relay which automatically changes the
connections from star to delta Figs 834 and 835 show the wiring and schematic diagrams for a star
delta starter
Objectives
1 Identify component and the specification
2 Design forward reverse star delta starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
2 ndash 99EASYTECH ENTERPRISE
REV -C
LEGENDMCCB Moulded Case Circuit BreakerTOR Thermal Over Load RelayFOW-C Mains Forward ContactorREV-C Mains Reverse ContactorDC Delta ContactorSC Star ContactorS-SW Mains Selector Switch
SC
V2
W2
U2
DC
V1
W1
U1
TOR
TOR
FOW-C
30A MCCB
TOR
MAIN CIRCUIT FORWARD REVERSE STAR DELTA
RYBN S
-SW
3 PHASEINDUCTION MOTOR
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Relay 10 A 240V 3
5 Triple pole Contactor
6 cw NO NC auxiliary contact
240Vac 20 A 4
7 Overload Relay 415 V 1
8 LED indicator 240vac 5 A 4
9 Start stop button 240Vac 5A 2
10 DIN rail 35 mm As required
11 Flexible wires 1 mm As required
12 Single core PVC insulated
wire
25 mm As required
13 Terminal block 20 A As required
14 Squirrel cage motor 5kW 1
15 5 pin plug and socket 415V 20A 1
16 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
3 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
a Manual star delta
b Manual Forward reverse star delta starter
c Automatic star delta starter
d Automatic Forward reverse star delta starter
4 Test the functionality of completed project
4 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
Objectives
1 Identify component and the specification
2 Design auto transformer starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
5 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Autotransformer starter is used to start a 3 phase induction motor that has a rating between 10 to 15 hp
6 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Autotransformer set 10Kw 415 V 50 Hz 1
5 Triple pole Contactor 240Vac 4
6 Batten type Lamp holder 240 Vac 105 A 4
7 Start stop button 240Vac 10A 4
8 Filament lamp (Bulb ) 240Vac 40W 4
9 DIN rail 35 mm As required
10 Flexible wires 1 mm As required
7 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
11 Single core PVC insulated
wire
25 mm As required
12 Terminal block 20 A As required
13 Squirrel cage motor 10kW 1
14 5 pin plug and socket 415V 20A 1
15 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a open transient autotransformer starter
b close transient autotransformer starter
c Forward reverse autotransformer starter
4 Test the functionality of completed project
8 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
Objectives
1 Identify component and the specification
2 Design rotor resistance starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
9 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Rotor Resistor set 10kW 1
5 Triple pole Contactor 240Vac 20A 4
6 Indicating light 240vac 5 A 4
7 Start stop push button 240Vac 5A 4
8 DIN rail 35 mm As required
9 Flexible wires 1 mm 2 As required
10 Single core PVC insulated wire 25 mm 2 As required
11 Terminal block 20 A As required
12 Slip Ring motor 10kW 1
13 5 pin round 3 phase socket 415V 20A 1
14 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
10 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
4 Test the functionality of completed project
a Dead circuit test b Life circuit test
5 Measure starting and running Amps
LESSON 16
TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
An installation in general will suffer damage
Damage usually occurs on the electric motor control as follows
1 Damage to the main circuit
2 Damage to the control circuit
The cause of the damage
i Overcurrent overload short circuit
ii Leakage current to ground
iii Equipment malfunction
iv The main control circuit
a Trip of main circuit protection devices fire
b Defect of motor terminal such as short circuit fire loose
v The control circuit is not functioning -
a contactor relay relay time overload relay does not work damaged burned
b Loose cable connection disconnected
Detecting and Repairing Damage
Examples of damage are as follows
i Motor does not work
ii Motor function and overload relay trips
iii Motor function but only partially functional control circuit
Methods of detecting damage
Among the known methods necessary to detect damage are as follows
1 Turn off the electricity at the main switch (main switch) in order to avoid any danger during the
work carried out to detect damage
2 Check all the protective gear that controls the motor control main circuit
11 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
3 Make sure the damage function control circuit
4 Check the control circuit according to the schematic circuit diagram of the motor control
5 Check the operation of the control circuit
Note
Use wiring that has been installed on the SYSTEM OF MOTOR CONTROL BOARD by Forward
Reverse control circuit for Star Delta to test and look for damage
SELF-ASSESSMENT QUESTIONS
1 (a) Explain what is meant by the term lsquoback emfrsquo in a motor
(b) Outline the basic differences between series shunt and compound wound dc motors
2 (a) With the aid of diagrams explain how the speed of series shunt and compound-wound motors
may be controlled
(b) A 440V dc shunt-wound motor has a field resistance of 200R and an armature resistance of 06 R
When its speed is 20 rev d second the current drawn from the supply is 122A Calculate its back
emf at this speed If the speed were decreased to 19 revssecond the field flux remaining unchanged
calculate the new back emf and the new armature current
3 A load of 64 kW at 240 V is supplied from the terminals of a shunt-wound dc generator The field
resistance is 180 A Calculate the armature current
4 (a) Explain with the aid of a diagram how a rotating magnetic field may be
(b) What is meant by lsquosynchronous speedrsquo
Calculate the synchronous obtained speed of a 12 pole motor if the supply frequency is 50Hz
5 (a) Explain the action of a synchronous motor
(b) What methods are available to start a synchronous motor Explain with diagrams
6 (a) Explain the action of a cage induction motor
(b) What is meant by the term lsquosliprsquo
Calculate the percentage slip of a six pole induction motor running at 162 revssecond from a 50 Hz
supply
7 Describe with sketches three different ways of starting a single-phase induction motor
12 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
8 Explain with the aid of a sketch the action of a three-phase DOL starter
What are dashpots used for How are remote start and stop buttons connected
9 A I0 kW 240V 50Hz single-phase cage rotor induction motor is 85efficient and has a PF of 068
lagging Calculate the motor current and the value of capacitor required to raise the PF to 093
lagging
10 Calculate the torque developed by an 18 kW four-pole induction motor run at 35 slip from a
50Hz supply
APPENDIX 1
13 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 11
14 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 111
Attachment Reference
httpswwwtlc-directcoukBook621htm
httpwwwstgovmyindexphpms
15 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
48 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify each component and the specification
2 Wire component according to the schematic diagram given
3 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting Board 450 x 600 mm Perforated metal 1
2 5 pin round socket and plug 415V ac 32A 1
3 Cut out fuse 60 A 3
4 Neutral link 1
5 kWatt hour meter 415V 60A 1
6 ELCB RCCB 3P+N In=63A415 Vac I trip= 300mA 1
7 ELCB RCCB 3P+N In=63A415 Vac I trip= 30mA 1
8 Single pole MCB 6A 240 V 3
9 Single pole MCB 20A 240 V 3
10 DOL starter 20 A 240Vac 2
11 Socket outlet 15 A 240 Vac 1
12 Switched Socket outlet 13 A 240 Vac 3
13 Led indicating light 5A 240 Vac 3
14 Single pole 4 gang 1 way switch 5A 240 Vac 2
15 Single pole 2 way switch 5A 240 Vac 2
16 1 phase induction motor 1 kW 240Vac 1
17 Metal trunking 30 mm x30 mm As required
18 Self tapping Wood screw 4 mm x 20 mm As required
19 DIN rail 25 mm x 1mm
20 GI steel rigid conduit 20mm As required
21 Flexible conduit 20mm As required
22 End box 20 mm 4
23 Flexible wires 05 mm 2 As required
24 Single core PVC insulated wire 15 mm 2 As required
25 Single core PVC insulated wires 25 mm 2 As required
26 Terminal block 10 A As required
Procedures
49 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify each components and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
4 Test the functionality of completed project
1 dead circuit test
2 life circuit
Note Proper earthing should be made
50 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 7 ndash WIRING SYSTEM OF THREE PHASE LIGHTING AND POWER CIRCUIT
51 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
52 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify component and the specification
2 Wire component according to the schematic diagram
3 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting bay Board Perforated metal 180 cm x 180 cm 1
2 k Watt hour meter 415V 60A 1
3 MCCB 415V 60A
4 ELCB RCCB In=60A415 Vac I trip=30mA 1
5 5 pin round Socket and
plug
415Vac 32A 4
6 Single pole MCB 6A 1
7 Triple pole MCB 20A 2
8 Triple pole Main switch 60A 1
9 DOL starter 240Vac 2
10 3 phase induction motor 2hp 415 Vac 1
11 1 phase induction motor 1
12 Metal trunking 30 mm x30 mm As required
13 Self tapping Wood screw 4 mm x 20 mm As required
14 DIN rail 25 mm x 1mm
15 GI steel rigid conduit 20mm As required
16 Flexible conduit 20mm As required
17 End box 20 mm 4
18 Flexible wires 05 mm As required
19 Connectors 10 A As required
Procedures
1 Identify each components and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
4 Test the functionality of completed project
1 dead circuit 2 life circuit test
5 Record the current drawn by the load as connected in star and delta
Note Proper earthing should be made
53 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 8 INSPECTION AND TESTING OF ELECTRICAL INSTALLATION
On completion of a wiring installation a number of tests on the installation have to be conducted to
ascertain that the wiring circuits and connected appliances are safe for use Prior to carrying out the
tests an inspection has to be done The results of the inspectionsupervision and test have to be
presented in Form G (as in Appendix IV) and Form H (as in Appendix V)
To have the test certification as in Form H the following tests shall be conducted
i Continuity Test
ii Insulation Resistance Test
iii Polarity Test
iv Earth Electrode Resistance test and
v Residual Current Device Test
1 Continuity Test
There are 3 main types of continuity tests for the final circuits-
i Protection Conductor Continuity Test
ii Final Ring Circuit Conductor Continuity Test
iii Live and Neutral Conductor Continuity Test
a) Protection Conductor Continuity Test
bull To ascertain that all protection conductors are connected in the correct and effective manner
bull Test equipment ndash Multimeter (Ohm range) or Ohm meter
54 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
bull Test Method
1 1048766 Ensure that the main switch RCD and MCB are open circuited (switched off) and all loads
are disconnected
2 1048766 Connected the test leads as in the Figure 81 The meter reading shall be less than 1 Ω
55 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Final Ring Circuit Conductor Continuity Test
bull To ensure that all conductors around the ring circuit have continuity
bull Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
bull Test Method
1 1048766 Disconnect both the supply source live conductors from the MCB the neutral conductor
from the neutral terminals and the earth conductor from the earth terminal in the distribution
fuse box
2 1048766 Connect the test leads as in the Figure 82 (EE)
3 1048766 Repeat the procedure for (L-L) and (N-N)
4 1048766 The meter reading value shall be less than 1 ohm
56 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Live and Neutral Conductor Continuity Test
a To ensure that each conductor in the circuit has continuity
b Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
2 Test Method
1 1048766 Switch off the Main switch RCD and MCB
2 1048766 Disconnect all loads
3 1048766 Switch on all switches in the circuit
4 1048766 Disconnect the fusesfinal circuit breakers and close the circuit
5 1048766 Carry out the test as shown in Figure 83
6 1048766 The meter reading value shall be less than 1Ω
57 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
58 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
CONTINUITY TEST
Insulation Resistance Test
i Ensure that there is no leakage current between phase conductors phase and neutral conductors and
phase conductor and earth
ii Test the strength of the cable insulation
iii Test Equipment ndash Insulation Resistance Tester operating voltage is 250VDC or 500VDC
iv Test Method
1 1048766 Switch off main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
59 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
4 1048766 Carry out test as in the Table below
5 1048766 Meter reading value shall be less than 1 Megaohm
60 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
61 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Insulation resitance test
62 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
INSULATION RESISTANCE TEST BETWEEN CONDUCTORS AND OPPOSITE POLARITY
Polarity Testi Ensure that each fuse or single pole control and protection device is connected only in the phase
conductor
ii Intermediate contact of Edison screw lamp holder is connected to the phase conductor
iii Ensure that phase neutral and earth conductors at socket outlets are connected at the correct
terminals
iv Test Equipment ndash Multimeter (Ohm range) or Ohm meter
v Test Method
1 1048766 Switch off Main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in Figure 85
63 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
5 1048766 Test switches and single phase control devices at the phase conductors
6 1048766 Test socket outlet connection sources
7 1048766 Test Edison screw lamp holder connections
8 1048766 Meter reading value shall be less than 1 Ω
64 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Polarity test
65 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Earth Electrode Resistance Testi To test the earth electrode resistance
ii To ascertain the suitability of the location of the electrode
iii To ensure that the electrode is not buried within the resistance area of another electrode
iv Test equipment ndash Earth Resistance Tester
v Test method -
1 1048766 Terminal rsquoErsquo is connected to the electrode to be tested (green conductor)
2 1048766 Terminal lsquoPrsquo is connected to the potential spike (yellow conductor) at a distance of 10
meters from the earth electrode
3 1048766 Terminal lsquoCrsquo is connected to the current spike (red conductor) at a distance of 20 meters
from the earth electrode
Earth Electrode Resistance Measurement Method (Figure 86)
This test must be repeated at least three times to ensure that the reading is not affected by interacting
earthing regions
i Record the first reading (Z1) Example Z1 = 10 Ω
ii Move the voltage spike to a distance of 6 meters from the original position Record the second
reading (Z2 ) Example Z2 = 10 Ω
iii Move the voltage spike to a distance of 6 meters from the original position Record the third
reading (Z3) Example Z3 = 10 Ω
66 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Residual Current Device Testi Ensure that the residual current device (RCD) trips within the set time on the occurrence of current
leakage to earth
ii Test Equipment ndash RCD Tester RCCB Tester
iii Test Method 1
1 1048766 Use the Trip Test Button
2 1048766 Press the trip button found on the RCD to determine if it trips or otherwise This test would
not be able to determine the sensitivity of the RCD nor the time taken for it to trip
iv Test Method 2
i 1048766 Use a RCD Tester
ii This equipment is equipped with a 13A plug which can be connected to a 13A socket outlet
Select the RCD sensitivity to be the same as the sensitivity of the RCD to be tested to
determine if the RCD can trip The time to trip shall not exceed 40 mS
iii 1048766 Test method ndash
a) Position the selection switch in accordance with the sensitivity of the RCD used
Example 100 mA 01 A
b) Position the operations switch to lsquoNo Triprsquo (frac12 Rated mA = 50) connect the 3 pin plug to
the 13A socket outlet
67 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
c) Switch on the 13A socket outlet ndash ensure that the P-N and P-E lights light up
This shows that the polarity is correct (Note if both the lights as above do not light up the test cannot
be continued)
d) Press the test button ndash the reading shows less than 200 mS and simultaneously the lsquotestrsquo light lights
up and the P-N and P-E lights do not light up At that instant the RCD will not trip
e) Move the selection switch to 180o (+ve wave) ndash repeat steps (d) and (e) Move the operations
switch to lsquoTriprsquo (Rated mA = 100)
g) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200mS
h) Move the selection switch to 0o (-ve wave)
i) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
j) The above test is repeated until a near correct reading is obtained
k) Record the test results
l) Change the operations switch to lsquoFast Triprsquo and press the test button ndash RCD will trip within a
time not exceeding 40 millisecond
m) Repeat a number of times at 0o or 180o
On completion of a wiring installation a number of tests on the installation have to be conducted to
ascertain that the wiring circuits and connected appliances are safe for use Prior to carrying out the
tests an inspection has to be done the following tests shall be conducted
i Continuity Test
ii Insulation Resistance Test
iii Polarity Test
iv Earth Electrode Resistance test and
v Residual Current Device Test
821 Continuity Test
There are 3 main types of continuity tests for the final circuits-
i Protection Conductor Continuity Test
ii Final Ring Circuit Conductor Continuity Test
68 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
iii Live and Neutral Conductor Continuity Test
a) Protection Conductor Continuity Test
bull To ascertain that all protection conductors are connected in the correct and effective manner
bull Test equipment ndash Multimeter (Ohm range) or Ohm meter
bull Test Method
1 1048766 Ensure that the main switch RCD and MCB are open circuited (switched off) and all loads are
disconnected
2 1048766 Connected the test leads as in the Figure 81
3 1048766 The meter reading shall be less than 1 Ω
Final Ring Circuit Conductor Continuity Test
bull To ensure that all conductors around the ring circuit have continuity
bull Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
bull Test Method
1 1048766 Disconnect both the supply source live conductors from the MCB the neutral conductor
from the neutral terminals and the earth conductor from the earth terminal in the distribution
fuse box
2 1048766 Connect the test leads as in the Figure 82 (EE)
3 1048766 Repeat the procedure for (L-L) and (N-N)
4 1048766 The meter reading value shall be less than 1 ohm Figure 82 - Final Ring Circuit Conductor
Continuity Test Ohm Meter
Disconnect both the supply source cables from mcbfuse
Take readings at earth conductors of both sources and note resistance readings
Live and Neutral Conductor Continuity Test
1 To ensure that each conductor in the circuit has continuity
2 Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
3 Test Method
1 1048766 Switch off the Main switch RCD and MCB
2 1048766 Disconnect all loads
3 1048766 Switch on all switches in the circuit
4 1048766 Disconnect the fusesfinal circuit breakers and close the circuit
5 1048766 Carry out the test as shown in Figure 83
6 1048766 The meter reading value shall be less than 1 ohm Figure 83 - Live and Neutral
Conductor Continuity Test Ohm Meter
Insulation Resistance Test
69 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
i Ensure that there is no leakage current between phase conductors phase and neutral conductors and
phase conductor and earth
ii Test the strength of the cable insulation
iii Test Equipment ndash Insulation Resistance Tester Operating voltage is 250VDC or 500VDC
iv Test Method
1 1048766 Switch off main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in the Table below
5 1048766 Meter reading value shall be less than 1 Megaohm
Polarity Test
i Ensure that each fuse or single pole control and protection device is connected only in the phase
conductor
ii Intermediate contact of Edison screw lamp holder is connected to the phase conductor
iii Ensure that phase neutral and earth conductors at socket outlets are connected at the correct
terminals
iv Test Equipment ndash Multimeter (Ohm range) or Ohm meter
v Test Method
1 1048766 Switch off Main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in Figure 85
5 1048766 Test switches and single phase control devices at the phase conductors
6 1048766 Test socket outlet connection sources
7 1048766 Test Edison screw lamp holder connections
8 1048766 Meter reading value shall be less than 1 Ω
Earth Electrode Resistance Test
i To test the earth electrode resistance
70 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
ii To ascertain the suitability of the location of the electrode
iii To ensure that the electrode is not buried within the resistance area of another electrode
iv Test equipment ndash Earth Resistance Tester
v Test method -
1 1048766 Terminal rsquoErsquo is connected to the electrode to be tested (green conductor)
2 1048766 Terminal lsquoPrsquo is connected to the potential spike (yellow conductor) at a distance of 10
meters from the earth electrode
3 1048766 Terminal lsquoCrsquo is connected to the current spike (red conductor) at a distance of 20 meters
from the earth electrode E P C Electrode 10 meter 10 meter
Figure 86 ndash Earth Electrode Resistance Measurement Test Equipment
Earth Electrode Resistance Measurement Method (Figure 86)
This test must be repeated at least three times to ensure that the reading is not affected by interacting
earthing regions
i Record the first reading (Z1) Example Z1 = 10 Ω
ii Move the voltage spike to a distance of 6 meters from the original position Record the second
reading (Z2) Example Z2 = 10 Ω
iii Move the voltage spike to a distance of 6 meters from the original position Record the third
reading (Z3)
Example Z3 = 10 Ω
Residual Current Device Test
71 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
i Ensure that the residual current device (RCD) trips within the set time on the occurrence of current
leakage to earth
ii Test Equipment ndash RCD Tester RCCB Tester
iii Test Method 1
1 1048766 Use the Trip Test Button
2 1048766 Press the trip button found on the RCD to determine if it trips or otherwise This test would
not be able to determine the sensitivity of the RCD nor the time taken for it to trip
iv Test Method 2
1048766 Use a RCD Tester
This equipment is equipped with a 13A plug which can be connected to a 13A socket outlet Select the
RCD sensitivity to be the same as the sensitivity of the RCD to be tested to determine if the RCD can
trip The time to trip shall not exceed 40 mS
1048766 Test method ndash
a) Position the selection switch in accordance with the sensitivity of the RCD used
Example 100 mA 01 A
b) Position the operations switch to lsquoNo Triprsquo (frac12 Rated mA = 50) connect the 3 pin plug to
the 13A socket outlet
c) Switch on the 13A socket outlet ndash ensure that the P-N and P-E lights light up This shows that
the polarity is correct (Note if both the lights as above do not light up the test cannot be
continued)
d) Press the test button ndash the reading shows less than 200 millisecond and simultaneously the
lsquotestrsquo light lights up and the P-N and P-E lights do not light up At that instant the RCD will
not trip
e) Move the selection switch to 180o (+ve wave) ndash repeat steps (d) and (e) = 100)
f) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
g) Move the selection switch to 0o (-ve wave)
h) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
i) The above test is repeated until a near correct reading is obtained
j) Record the test results
k) Change the operations switch to lsquoFast Triprsquo and press the test button ndash RCD will trip within a
time not exceeding 40 mS
l) Repeat a number of times at 0o or 180o
72 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 9 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (DC)
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
73 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Start stop button 240Vac 5A 2
9 Filament lamp (Bulb ) 240Vac 40W 3
10 Overload Relay 415V 20A 3
11 Three phase induction motor 5 hp 3
12 Single phase step down transformer 2500VA 1
13 Single core PVC insulated Cable 1mm 2 As required
14 Single core PVC insulated Cable 25mm 2 As required
15 DIN rail 35 mm As required
16 PVC type Cable tray 50 mm x 50 mm As required
17 Cable ties 4 ldquo As required
18 Flexible wires 05 mm As required
19 PVC Connectors 5 A amp 20 A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the schematic
diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a optional exercise
i Simple DOL starter
ii Forward reverse DOL starter
iii Forward Reverse Dahlander motor
iv Three motors operated in sequence by DOL starter operated by manual push
button or time delay relay
74 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
a One loop per-cycle
b Continuous operation in a loop
c optional circuit design to represent the same task
v Only one out of three motors to be operated at a time (quiz)
4 Test the functionality of completed project
LESSON 10 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (AC)
75 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 1
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Lamp point 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
76 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
11 Overload Relay 415V 20A 3
12 Three phase induction
motor
5 hp 3
13 Single core PVC insulated
Cable
1mm 2 As required
14 Single core PVC insulated
Cable
25mm 2 As required
15 DIN rail 35 mm As required
16 PVC type Cable tray 50 mm x 50 mm As required
17 Cable ties 4 ldquo As required
18 Flexible wires 05 mm As required
19 PVC Connectors 5 A amp 20 A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the
schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram optional exercise
4 Simple DOL starter
5 Forward reverse DOL starter
6 Test the functionality of completed project
77 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 1
78 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
cm
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Indicating light 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
11 Overload Relay 415V 20A 3
12 Three phase induction motor 5 hp 3
13 Single phase step down
transformer
2500VA 1
14 Single core PVC insulated
Cable
1mm 2 As required
15 Single core PVC insulated
Cable
25mm 2 As required
16 DIN rail 35 mm As required
17 PVC type Cable tray 50 mm x 50 mm As required
18 Cable ties 4 ldquo As required
19 Flexible wires 05 mm As required
20 PVC Connectors 5 A amp 20 A 240 V As required
21 Single pole MCB 6A 240 V 1
22 Single pole MCB 2A 240 V 1
23 Triple pole MCB 20A 415 V 1
24 Mounting board 30 cm x 40 cm x 3
cm
1
25 Relay cw 11 pin socket 10 A 240 Vac 2
26 Time delay relay 10 A 240 Vac 3
27 Triple pole Contactor 20A 240Vac 3
28 Batten type Lamp holder 240Vac 10 A 3
29 Start stop button 240Vac 10A 2
30 Indicating light (Bulb ) 240Vac 25W 3
31 Overload Relay 415V 20A 1
32 Three phase dahlander type
induction motor
5 hp 1
33 Single phase step down
transformer
24024Vac
2500VA
1
79 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
34 Single core PVC insulated
Cable
1mm 2 As required
35 Single core PVC insulated
Cable
25mm 2 As required
36 DIN rail 35 mm As required
37 PVC type Cable tray 50 mm x 50 mm As required
38 Cable ties 4 ldquo As required
39 Flexible wires 075 mm As required
40 PVC Connectors 5 A amp 20 A 240 V As required
41 Terminal block 20A 240Vac As required
Procedures
5 Identify each component according to specification and quantity required from the schematic
diagram attached
6 Test the functionality of each component by using multi-meter or power supply whichever
applicable
7 Wire component according to circuit diagram
8 Three motors operated in sequence by DOL starter operated by manual push button or time
delay relay
a One loop per-cycle
b Continuous operation in a loop
c optional circuit design to represent the same task
d Only one out of three motors to be operated at a time (quiz)
9 Test the functionality of completed project
80 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
BASIC DESIGN INDUSTRIAL MOTOR CONTROL (SEQUENCE CONTROL)
THREE PHASE INDUCTION MOTOR OPERATED IN SEQUENCE BY DIRECT ON LINE
STARTER
LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
81 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
82 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Lcd lamp indicator 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
11 Overload Relay 415V 20A 3
12 Three phase induction motor 5 hp 3
13 Single phase step down transformer 2500VA 1
14 Single core PVC insulated Cable 1mm 2 As required
15 Single core PVC insulated Cable 25mm 2 As required
16 DIN rail 35 mm As required
17 PVC type Cable tray 50 mm x 50 mm As required
18 Cable ties 4 ldquo As required
19 Flexible wires 1 mm Oslash As required
20 PVC Terminal block 10A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the schematic
diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a optional exercise
i Forward Reverse dahlander motor
4 Test the functionality of completed project
83 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
THREE PHASE DAHLANDER TYPE INDUCTION MOTOR OPERATED FORWARD AND
REVERSE OPERATION BY DIRECT ON LINE STARTER
84 ndash 99EASYTECH ENTERPRISE
LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
Introduction
If a motors windings are connected in the star configuration any two phases will be in series across
the supply and hence the line current will be smaller(by 577) than if the windings were connected in
the delta arrangement
Hence larger-type motors with heavy starting currents are first connected in star and then when the
starting currents fall in delta This of course means that all six of the ends of the windings must be
brought to terminations outside the casing (Fig 833)
EZTECH
EZTECH ELECTRICAL INSTALLATION GUIDE
The automatic version of this starter incorporates a timing relay which automatically changes the
connections from star to delta Figs 834 and 835 show the wiring and schematic diagrams for a star
delta starter
Objectives
1 Identify component and the specification
2 Design forward reverse star delta starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
2 ndash 99EASYTECH ENTERPRISE
REV -C
LEGENDMCCB Moulded Case Circuit BreakerTOR Thermal Over Load RelayFOW-C Mains Forward ContactorREV-C Mains Reverse ContactorDC Delta ContactorSC Star ContactorS-SW Mains Selector Switch
SC
V2
W2
U2
DC
V1
W1
U1
TOR
TOR
FOW-C
30A MCCB
TOR
MAIN CIRCUIT FORWARD REVERSE STAR DELTA
RYBN S
-SW
3 PHASEINDUCTION MOTOR
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Relay 10 A 240V 3
5 Triple pole Contactor
6 cw NO NC auxiliary contact
240Vac 20 A 4
7 Overload Relay 415 V 1
8 LED indicator 240vac 5 A 4
9 Start stop button 240Vac 5A 2
10 DIN rail 35 mm As required
11 Flexible wires 1 mm As required
12 Single core PVC insulated
wire
25 mm As required
13 Terminal block 20 A As required
14 Squirrel cage motor 5kW 1
15 5 pin plug and socket 415V 20A 1
16 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
3 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
a Manual star delta
b Manual Forward reverse star delta starter
c Automatic star delta starter
d Automatic Forward reverse star delta starter
4 Test the functionality of completed project
4 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
Objectives
1 Identify component and the specification
2 Design auto transformer starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
5 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Autotransformer starter is used to start a 3 phase induction motor that has a rating between 10 to 15 hp
6 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Autotransformer set 10Kw 415 V 50 Hz 1
5 Triple pole Contactor 240Vac 4
6 Batten type Lamp holder 240 Vac 105 A 4
7 Start stop button 240Vac 10A 4
8 Filament lamp (Bulb ) 240Vac 40W 4
9 DIN rail 35 mm As required
10 Flexible wires 1 mm As required
7 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
11 Single core PVC insulated
wire
25 mm As required
12 Terminal block 20 A As required
13 Squirrel cage motor 10kW 1
14 5 pin plug and socket 415V 20A 1
15 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a open transient autotransformer starter
b close transient autotransformer starter
c Forward reverse autotransformer starter
4 Test the functionality of completed project
8 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
Objectives
1 Identify component and the specification
2 Design rotor resistance starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
9 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Rotor Resistor set 10kW 1
5 Triple pole Contactor 240Vac 20A 4
6 Indicating light 240vac 5 A 4
7 Start stop push button 240Vac 5A 4
8 DIN rail 35 mm As required
9 Flexible wires 1 mm 2 As required
10 Single core PVC insulated wire 25 mm 2 As required
11 Terminal block 20 A As required
12 Slip Ring motor 10kW 1
13 5 pin round 3 phase socket 415V 20A 1
14 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
10 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
4 Test the functionality of completed project
a Dead circuit test b Life circuit test
5 Measure starting and running Amps
LESSON 16
TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
An installation in general will suffer damage
Damage usually occurs on the electric motor control as follows
1 Damage to the main circuit
2 Damage to the control circuit
The cause of the damage
i Overcurrent overload short circuit
ii Leakage current to ground
iii Equipment malfunction
iv The main control circuit
a Trip of main circuit protection devices fire
b Defect of motor terminal such as short circuit fire loose
v The control circuit is not functioning -
a contactor relay relay time overload relay does not work damaged burned
b Loose cable connection disconnected
Detecting and Repairing Damage
Examples of damage are as follows
i Motor does not work
ii Motor function and overload relay trips
iii Motor function but only partially functional control circuit
Methods of detecting damage
Among the known methods necessary to detect damage are as follows
1 Turn off the electricity at the main switch (main switch) in order to avoid any danger during the
work carried out to detect damage
2 Check all the protective gear that controls the motor control main circuit
11 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
3 Make sure the damage function control circuit
4 Check the control circuit according to the schematic circuit diagram of the motor control
5 Check the operation of the control circuit
Note
Use wiring that has been installed on the SYSTEM OF MOTOR CONTROL BOARD by Forward
Reverse control circuit for Star Delta to test and look for damage
SELF-ASSESSMENT QUESTIONS
1 (a) Explain what is meant by the term lsquoback emfrsquo in a motor
(b) Outline the basic differences between series shunt and compound wound dc motors
2 (a) With the aid of diagrams explain how the speed of series shunt and compound-wound motors
may be controlled
(b) A 440V dc shunt-wound motor has a field resistance of 200R and an armature resistance of 06 R
When its speed is 20 rev d second the current drawn from the supply is 122A Calculate its back
emf at this speed If the speed were decreased to 19 revssecond the field flux remaining unchanged
calculate the new back emf and the new armature current
3 A load of 64 kW at 240 V is supplied from the terminals of a shunt-wound dc generator The field
resistance is 180 A Calculate the armature current
4 (a) Explain with the aid of a diagram how a rotating magnetic field may be
(b) What is meant by lsquosynchronous speedrsquo
Calculate the synchronous obtained speed of a 12 pole motor if the supply frequency is 50Hz
5 (a) Explain the action of a synchronous motor
(b) What methods are available to start a synchronous motor Explain with diagrams
6 (a) Explain the action of a cage induction motor
(b) What is meant by the term lsquosliprsquo
Calculate the percentage slip of a six pole induction motor running at 162 revssecond from a 50 Hz
supply
7 Describe with sketches three different ways of starting a single-phase induction motor
12 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
8 Explain with the aid of a sketch the action of a three-phase DOL starter
What are dashpots used for How are remote start and stop buttons connected
9 A I0 kW 240V 50Hz single-phase cage rotor induction motor is 85efficient and has a PF of 068
lagging Calculate the motor current and the value of capacitor required to raise the PF to 093
lagging
10 Calculate the torque developed by an 18 kW four-pole induction motor run at 35 slip from a
50Hz supply
APPENDIX 1
13 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 11
14 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 111
Attachment Reference
httpswwwtlc-directcoukBook621htm
httpwwwstgovmyindexphpms
15 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify each component and the specification
2 Wire component according to the schematic diagram given
3 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting Board 450 x 600 mm Perforated metal 1
2 5 pin round socket and plug 415V ac 32A 1
3 Cut out fuse 60 A 3
4 Neutral link 1
5 kWatt hour meter 415V 60A 1
6 ELCB RCCB 3P+N In=63A415 Vac I trip= 300mA 1
7 ELCB RCCB 3P+N In=63A415 Vac I trip= 30mA 1
8 Single pole MCB 6A 240 V 3
9 Single pole MCB 20A 240 V 3
10 DOL starter 20 A 240Vac 2
11 Socket outlet 15 A 240 Vac 1
12 Switched Socket outlet 13 A 240 Vac 3
13 Led indicating light 5A 240 Vac 3
14 Single pole 4 gang 1 way switch 5A 240 Vac 2
15 Single pole 2 way switch 5A 240 Vac 2
16 1 phase induction motor 1 kW 240Vac 1
17 Metal trunking 30 mm x30 mm As required
18 Self tapping Wood screw 4 mm x 20 mm As required
19 DIN rail 25 mm x 1mm
20 GI steel rigid conduit 20mm As required
21 Flexible conduit 20mm As required
22 End box 20 mm 4
23 Flexible wires 05 mm 2 As required
24 Single core PVC insulated wire 15 mm 2 As required
25 Single core PVC insulated wires 25 mm 2 As required
26 Terminal block 10 A As required
Procedures
49 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify each components and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
4 Test the functionality of completed project
1 dead circuit test
2 life circuit
Note Proper earthing should be made
50 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 7 ndash WIRING SYSTEM OF THREE PHASE LIGHTING AND POWER CIRCUIT
51 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
52 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify component and the specification
2 Wire component according to the schematic diagram
3 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting bay Board Perforated metal 180 cm x 180 cm 1
2 k Watt hour meter 415V 60A 1
3 MCCB 415V 60A
4 ELCB RCCB In=60A415 Vac I trip=30mA 1
5 5 pin round Socket and
plug
415Vac 32A 4
6 Single pole MCB 6A 1
7 Triple pole MCB 20A 2
8 Triple pole Main switch 60A 1
9 DOL starter 240Vac 2
10 3 phase induction motor 2hp 415 Vac 1
11 1 phase induction motor 1
12 Metal trunking 30 mm x30 mm As required
13 Self tapping Wood screw 4 mm x 20 mm As required
14 DIN rail 25 mm x 1mm
15 GI steel rigid conduit 20mm As required
16 Flexible conduit 20mm As required
17 End box 20 mm 4
18 Flexible wires 05 mm As required
19 Connectors 10 A As required
Procedures
1 Identify each components and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
4 Test the functionality of completed project
1 dead circuit 2 life circuit test
5 Record the current drawn by the load as connected in star and delta
Note Proper earthing should be made
53 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 8 INSPECTION AND TESTING OF ELECTRICAL INSTALLATION
On completion of a wiring installation a number of tests on the installation have to be conducted to
ascertain that the wiring circuits and connected appliances are safe for use Prior to carrying out the
tests an inspection has to be done The results of the inspectionsupervision and test have to be
presented in Form G (as in Appendix IV) and Form H (as in Appendix V)
To have the test certification as in Form H the following tests shall be conducted
i Continuity Test
ii Insulation Resistance Test
iii Polarity Test
iv Earth Electrode Resistance test and
v Residual Current Device Test
1 Continuity Test
There are 3 main types of continuity tests for the final circuits-
i Protection Conductor Continuity Test
ii Final Ring Circuit Conductor Continuity Test
iii Live and Neutral Conductor Continuity Test
a) Protection Conductor Continuity Test
bull To ascertain that all protection conductors are connected in the correct and effective manner
bull Test equipment ndash Multimeter (Ohm range) or Ohm meter
54 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
bull Test Method
1 1048766 Ensure that the main switch RCD and MCB are open circuited (switched off) and all loads
are disconnected
2 1048766 Connected the test leads as in the Figure 81 The meter reading shall be less than 1 Ω
55 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Final Ring Circuit Conductor Continuity Test
bull To ensure that all conductors around the ring circuit have continuity
bull Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
bull Test Method
1 1048766 Disconnect both the supply source live conductors from the MCB the neutral conductor
from the neutral terminals and the earth conductor from the earth terminal in the distribution
fuse box
2 1048766 Connect the test leads as in the Figure 82 (EE)
3 1048766 Repeat the procedure for (L-L) and (N-N)
4 1048766 The meter reading value shall be less than 1 ohm
56 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Live and Neutral Conductor Continuity Test
a To ensure that each conductor in the circuit has continuity
b Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
2 Test Method
1 1048766 Switch off the Main switch RCD and MCB
2 1048766 Disconnect all loads
3 1048766 Switch on all switches in the circuit
4 1048766 Disconnect the fusesfinal circuit breakers and close the circuit
5 1048766 Carry out the test as shown in Figure 83
6 1048766 The meter reading value shall be less than 1Ω
57 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
58 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
CONTINUITY TEST
Insulation Resistance Test
i Ensure that there is no leakage current between phase conductors phase and neutral conductors and
phase conductor and earth
ii Test the strength of the cable insulation
iii Test Equipment ndash Insulation Resistance Tester operating voltage is 250VDC or 500VDC
iv Test Method
1 1048766 Switch off main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
59 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
4 1048766 Carry out test as in the Table below
5 1048766 Meter reading value shall be less than 1 Megaohm
60 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
61 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Insulation resitance test
62 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
INSULATION RESISTANCE TEST BETWEEN CONDUCTORS AND OPPOSITE POLARITY
Polarity Testi Ensure that each fuse or single pole control and protection device is connected only in the phase
conductor
ii Intermediate contact of Edison screw lamp holder is connected to the phase conductor
iii Ensure that phase neutral and earth conductors at socket outlets are connected at the correct
terminals
iv Test Equipment ndash Multimeter (Ohm range) or Ohm meter
v Test Method
1 1048766 Switch off Main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in Figure 85
63 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
5 1048766 Test switches and single phase control devices at the phase conductors
6 1048766 Test socket outlet connection sources
7 1048766 Test Edison screw lamp holder connections
8 1048766 Meter reading value shall be less than 1 Ω
64 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Polarity test
65 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Earth Electrode Resistance Testi To test the earth electrode resistance
ii To ascertain the suitability of the location of the electrode
iii To ensure that the electrode is not buried within the resistance area of another electrode
iv Test equipment ndash Earth Resistance Tester
v Test method -
1 1048766 Terminal rsquoErsquo is connected to the electrode to be tested (green conductor)
2 1048766 Terminal lsquoPrsquo is connected to the potential spike (yellow conductor) at a distance of 10
meters from the earth electrode
3 1048766 Terminal lsquoCrsquo is connected to the current spike (red conductor) at a distance of 20 meters
from the earth electrode
Earth Electrode Resistance Measurement Method (Figure 86)
This test must be repeated at least three times to ensure that the reading is not affected by interacting
earthing regions
i Record the first reading (Z1) Example Z1 = 10 Ω
ii Move the voltage spike to a distance of 6 meters from the original position Record the second
reading (Z2 ) Example Z2 = 10 Ω
iii Move the voltage spike to a distance of 6 meters from the original position Record the third
reading (Z3) Example Z3 = 10 Ω
66 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Residual Current Device Testi Ensure that the residual current device (RCD) trips within the set time on the occurrence of current
leakage to earth
ii Test Equipment ndash RCD Tester RCCB Tester
iii Test Method 1
1 1048766 Use the Trip Test Button
2 1048766 Press the trip button found on the RCD to determine if it trips or otherwise This test would
not be able to determine the sensitivity of the RCD nor the time taken for it to trip
iv Test Method 2
i 1048766 Use a RCD Tester
ii This equipment is equipped with a 13A plug which can be connected to a 13A socket outlet
Select the RCD sensitivity to be the same as the sensitivity of the RCD to be tested to
determine if the RCD can trip The time to trip shall not exceed 40 mS
iii 1048766 Test method ndash
a) Position the selection switch in accordance with the sensitivity of the RCD used
Example 100 mA 01 A
b) Position the operations switch to lsquoNo Triprsquo (frac12 Rated mA = 50) connect the 3 pin plug to
the 13A socket outlet
67 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
c) Switch on the 13A socket outlet ndash ensure that the P-N and P-E lights light up
This shows that the polarity is correct (Note if both the lights as above do not light up the test cannot
be continued)
d) Press the test button ndash the reading shows less than 200 mS and simultaneously the lsquotestrsquo light lights
up and the P-N and P-E lights do not light up At that instant the RCD will not trip
e) Move the selection switch to 180o (+ve wave) ndash repeat steps (d) and (e) Move the operations
switch to lsquoTriprsquo (Rated mA = 100)
g) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200mS
h) Move the selection switch to 0o (-ve wave)
i) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
j) The above test is repeated until a near correct reading is obtained
k) Record the test results
l) Change the operations switch to lsquoFast Triprsquo and press the test button ndash RCD will trip within a
time not exceeding 40 millisecond
m) Repeat a number of times at 0o or 180o
On completion of a wiring installation a number of tests on the installation have to be conducted to
ascertain that the wiring circuits and connected appliances are safe for use Prior to carrying out the
tests an inspection has to be done the following tests shall be conducted
i Continuity Test
ii Insulation Resistance Test
iii Polarity Test
iv Earth Electrode Resistance test and
v Residual Current Device Test
821 Continuity Test
There are 3 main types of continuity tests for the final circuits-
i Protection Conductor Continuity Test
ii Final Ring Circuit Conductor Continuity Test
68 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
iii Live and Neutral Conductor Continuity Test
a) Protection Conductor Continuity Test
bull To ascertain that all protection conductors are connected in the correct and effective manner
bull Test equipment ndash Multimeter (Ohm range) or Ohm meter
bull Test Method
1 1048766 Ensure that the main switch RCD and MCB are open circuited (switched off) and all loads are
disconnected
2 1048766 Connected the test leads as in the Figure 81
3 1048766 The meter reading shall be less than 1 Ω
Final Ring Circuit Conductor Continuity Test
bull To ensure that all conductors around the ring circuit have continuity
bull Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
bull Test Method
1 1048766 Disconnect both the supply source live conductors from the MCB the neutral conductor
from the neutral terminals and the earth conductor from the earth terminal in the distribution
fuse box
2 1048766 Connect the test leads as in the Figure 82 (EE)
3 1048766 Repeat the procedure for (L-L) and (N-N)
4 1048766 The meter reading value shall be less than 1 ohm Figure 82 - Final Ring Circuit Conductor
Continuity Test Ohm Meter
Disconnect both the supply source cables from mcbfuse
Take readings at earth conductors of both sources and note resistance readings
Live and Neutral Conductor Continuity Test
1 To ensure that each conductor in the circuit has continuity
2 Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
3 Test Method
1 1048766 Switch off the Main switch RCD and MCB
2 1048766 Disconnect all loads
3 1048766 Switch on all switches in the circuit
4 1048766 Disconnect the fusesfinal circuit breakers and close the circuit
5 1048766 Carry out the test as shown in Figure 83
6 1048766 The meter reading value shall be less than 1 ohm Figure 83 - Live and Neutral
Conductor Continuity Test Ohm Meter
Insulation Resistance Test
69 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
i Ensure that there is no leakage current between phase conductors phase and neutral conductors and
phase conductor and earth
ii Test the strength of the cable insulation
iii Test Equipment ndash Insulation Resistance Tester Operating voltage is 250VDC or 500VDC
iv Test Method
1 1048766 Switch off main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in the Table below
5 1048766 Meter reading value shall be less than 1 Megaohm
Polarity Test
i Ensure that each fuse or single pole control and protection device is connected only in the phase
conductor
ii Intermediate contact of Edison screw lamp holder is connected to the phase conductor
iii Ensure that phase neutral and earth conductors at socket outlets are connected at the correct
terminals
iv Test Equipment ndash Multimeter (Ohm range) or Ohm meter
v Test Method
1 1048766 Switch off Main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in Figure 85
5 1048766 Test switches and single phase control devices at the phase conductors
6 1048766 Test socket outlet connection sources
7 1048766 Test Edison screw lamp holder connections
8 1048766 Meter reading value shall be less than 1 Ω
Earth Electrode Resistance Test
i To test the earth electrode resistance
70 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
ii To ascertain the suitability of the location of the electrode
iii To ensure that the electrode is not buried within the resistance area of another electrode
iv Test equipment ndash Earth Resistance Tester
v Test method -
1 1048766 Terminal rsquoErsquo is connected to the electrode to be tested (green conductor)
2 1048766 Terminal lsquoPrsquo is connected to the potential spike (yellow conductor) at a distance of 10
meters from the earth electrode
3 1048766 Terminal lsquoCrsquo is connected to the current spike (red conductor) at a distance of 20 meters
from the earth electrode E P C Electrode 10 meter 10 meter
Figure 86 ndash Earth Electrode Resistance Measurement Test Equipment
Earth Electrode Resistance Measurement Method (Figure 86)
This test must be repeated at least three times to ensure that the reading is not affected by interacting
earthing regions
i Record the first reading (Z1) Example Z1 = 10 Ω
ii Move the voltage spike to a distance of 6 meters from the original position Record the second
reading (Z2) Example Z2 = 10 Ω
iii Move the voltage spike to a distance of 6 meters from the original position Record the third
reading (Z3)
Example Z3 = 10 Ω
Residual Current Device Test
71 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
i Ensure that the residual current device (RCD) trips within the set time on the occurrence of current
leakage to earth
ii Test Equipment ndash RCD Tester RCCB Tester
iii Test Method 1
1 1048766 Use the Trip Test Button
2 1048766 Press the trip button found on the RCD to determine if it trips or otherwise This test would
not be able to determine the sensitivity of the RCD nor the time taken for it to trip
iv Test Method 2
1048766 Use a RCD Tester
This equipment is equipped with a 13A plug which can be connected to a 13A socket outlet Select the
RCD sensitivity to be the same as the sensitivity of the RCD to be tested to determine if the RCD can
trip The time to trip shall not exceed 40 mS
1048766 Test method ndash
a) Position the selection switch in accordance with the sensitivity of the RCD used
Example 100 mA 01 A
b) Position the operations switch to lsquoNo Triprsquo (frac12 Rated mA = 50) connect the 3 pin plug to
the 13A socket outlet
c) Switch on the 13A socket outlet ndash ensure that the P-N and P-E lights light up This shows that
the polarity is correct (Note if both the lights as above do not light up the test cannot be
continued)
d) Press the test button ndash the reading shows less than 200 millisecond and simultaneously the
lsquotestrsquo light lights up and the P-N and P-E lights do not light up At that instant the RCD will
not trip
e) Move the selection switch to 180o (+ve wave) ndash repeat steps (d) and (e) = 100)
f) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
g) Move the selection switch to 0o (-ve wave)
h) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
i) The above test is repeated until a near correct reading is obtained
j) Record the test results
k) Change the operations switch to lsquoFast Triprsquo and press the test button ndash RCD will trip within a
time not exceeding 40 mS
l) Repeat a number of times at 0o or 180o
72 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 9 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (DC)
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
73 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Start stop button 240Vac 5A 2
9 Filament lamp (Bulb ) 240Vac 40W 3
10 Overload Relay 415V 20A 3
11 Three phase induction motor 5 hp 3
12 Single phase step down transformer 2500VA 1
13 Single core PVC insulated Cable 1mm 2 As required
14 Single core PVC insulated Cable 25mm 2 As required
15 DIN rail 35 mm As required
16 PVC type Cable tray 50 mm x 50 mm As required
17 Cable ties 4 ldquo As required
18 Flexible wires 05 mm As required
19 PVC Connectors 5 A amp 20 A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the schematic
diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a optional exercise
i Simple DOL starter
ii Forward reverse DOL starter
iii Forward Reverse Dahlander motor
iv Three motors operated in sequence by DOL starter operated by manual push
button or time delay relay
74 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
a One loop per-cycle
b Continuous operation in a loop
c optional circuit design to represent the same task
v Only one out of three motors to be operated at a time (quiz)
4 Test the functionality of completed project
LESSON 10 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (AC)
75 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 1
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Lamp point 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
76 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
11 Overload Relay 415V 20A 3
12 Three phase induction
motor
5 hp 3
13 Single core PVC insulated
Cable
1mm 2 As required
14 Single core PVC insulated
Cable
25mm 2 As required
15 DIN rail 35 mm As required
16 PVC type Cable tray 50 mm x 50 mm As required
17 Cable ties 4 ldquo As required
18 Flexible wires 05 mm As required
19 PVC Connectors 5 A amp 20 A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the
schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram optional exercise
4 Simple DOL starter
5 Forward reverse DOL starter
6 Test the functionality of completed project
77 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 1
78 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
cm
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Indicating light 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
11 Overload Relay 415V 20A 3
12 Three phase induction motor 5 hp 3
13 Single phase step down
transformer
2500VA 1
14 Single core PVC insulated
Cable
1mm 2 As required
15 Single core PVC insulated
Cable
25mm 2 As required
16 DIN rail 35 mm As required
17 PVC type Cable tray 50 mm x 50 mm As required
18 Cable ties 4 ldquo As required
19 Flexible wires 05 mm As required
20 PVC Connectors 5 A amp 20 A 240 V As required
21 Single pole MCB 6A 240 V 1
22 Single pole MCB 2A 240 V 1
23 Triple pole MCB 20A 415 V 1
24 Mounting board 30 cm x 40 cm x 3
cm
1
25 Relay cw 11 pin socket 10 A 240 Vac 2
26 Time delay relay 10 A 240 Vac 3
27 Triple pole Contactor 20A 240Vac 3
28 Batten type Lamp holder 240Vac 10 A 3
29 Start stop button 240Vac 10A 2
30 Indicating light (Bulb ) 240Vac 25W 3
31 Overload Relay 415V 20A 1
32 Three phase dahlander type
induction motor
5 hp 1
33 Single phase step down
transformer
24024Vac
2500VA
1
79 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
34 Single core PVC insulated
Cable
1mm 2 As required
35 Single core PVC insulated
Cable
25mm 2 As required
36 DIN rail 35 mm As required
37 PVC type Cable tray 50 mm x 50 mm As required
38 Cable ties 4 ldquo As required
39 Flexible wires 075 mm As required
40 PVC Connectors 5 A amp 20 A 240 V As required
41 Terminal block 20A 240Vac As required
Procedures
5 Identify each component according to specification and quantity required from the schematic
diagram attached
6 Test the functionality of each component by using multi-meter or power supply whichever
applicable
7 Wire component according to circuit diagram
8 Three motors operated in sequence by DOL starter operated by manual push button or time
delay relay
a One loop per-cycle
b Continuous operation in a loop
c optional circuit design to represent the same task
d Only one out of three motors to be operated at a time (quiz)
9 Test the functionality of completed project
80 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
BASIC DESIGN INDUSTRIAL MOTOR CONTROL (SEQUENCE CONTROL)
THREE PHASE INDUCTION MOTOR OPERATED IN SEQUENCE BY DIRECT ON LINE
STARTER
LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
81 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
82 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Lcd lamp indicator 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
11 Overload Relay 415V 20A 3
12 Three phase induction motor 5 hp 3
13 Single phase step down transformer 2500VA 1
14 Single core PVC insulated Cable 1mm 2 As required
15 Single core PVC insulated Cable 25mm 2 As required
16 DIN rail 35 mm As required
17 PVC type Cable tray 50 mm x 50 mm As required
18 Cable ties 4 ldquo As required
19 Flexible wires 1 mm Oslash As required
20 PVC Terminal block 10A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the schematic
diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a optional exercise
i Forward Reverse dahlander motor
4 Test the functionality of completed project
83 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
THREE PHASE DAHLANDER TYPE INDUCTION MOTOR OPERATED FORWARD AND
REVERSE OPERATION BY DIRECT ON LINE STARTER
84 ndash 99EASYTECH ENTERPRISE
LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
Introduction
If a motors windings are connected in the star configuration any two phases will be in series across
the supply and hence the line current will be smaller(by 577) than if the windings were connected in
the delta arrangement
Hence larger-type motors with heavy starting currents are first connected in star and then when the
starting currents fall in delta This of course means that all six of the ends of the windings must be
brought to terminations outside the casing (Fig 833)
EZTECH
EZTECH ELECTRICAL INSTALLATION GUIDE
The automatic version of this starter incorporates a timing relay which automatically changes the
connections from star to delta Figs 834 and 835 show the wiring and schematic diagrams for a star
delta starter
Objectives
1 Identify component and the specification
2 Design forward reverse star delta starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
2 ndash 99EASYTECH ENTERPRISE
REV -C
LEGENDMCCB Moulded Case Circuit BreakerTOR Thermal Over Load RelayFOW-C Mains Forward ContactorREV-C Mains Reverse ContactorDC Delta ContactorSC Star ContactorS-SW Mains Selector Switch
SC
V2
W2
U2
DC
V1
W1
U1
TOR
TOR
FOW-C
30A MCCB
TOR
MAIN CIRCUIT FORWARD REVERSE STAR DELTA
RYBN S
-SW
3 PHASEINDUCTION MOTOR
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Relay 10 A 240V 3
5 Triple pole Contactor
6 cw NO NC auxiliary contact
240Vac 20 A 4
7 Overload Relay 415 V 1
8 LED indicator 240vac 5 A 4
9 Start stop button 240Vac 5A 2
10 DIN rail 35 mm As required
11 Flexible wires 1 mm As required
12 Single core PVC insulated
wire
25 mm As required
13 Terminal block 20 A As required
14 Squirrel cage motor 5kW 1
15 5 pin plug and socket 415V 20A 1
16 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
3 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
a Manual star delta
b Manual Forward reverse star delta starter
c Automatic star delta starter
d Automatic Forward reverse star delta starter
4 Test the functionality of completed project
4 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
Objectives
1 Identify component and the specification
2 Design auto transformer starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
5 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Autotransformer starter is used to start a 3 phase induction motor that has a rating between 10 to 15 hp
6 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Autotransformer set 10Kw 415 V 50 Hz 1
5 Triple pole Contactor 240Vac 4
6 Batten type Lamp holder 240 Vac 105 A 4
7 Start stop button 240Vac 10A 4
8 Filament lamp (Bulb ) 240Vac 40W 4
9 DIN rail 35 mm As required
10 Flexible wires 1 mm As required
7 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
11 Single core PVC insulated
wire
25 mm As required
12 Terminal block 20 A As required
13 Squirrel cage motor 10kW 1
14 5 pin plug and socket 415V 20A 1
15 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a open transient autotransformer starter
b close transient autotransformer starter
c Forward reverse autotransformer starter
4 Test the functionality of completed project
8 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
Objectives
1 Identify component and the specification
2 Design rotor resistance starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
9 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Rotor Resistor set 10kW 1
5 Triple pole Contactor 240Vac 20A 4
6 Indicating light 240vac 5 A 4
7 Start stop push button 240Vac 5A 4
8 DIN rail 35 mm As required
9 Flexible wires 1 mm 2 As required
10 Single core PVC insulated wire 25 mm 2 As required
11 Terminal block 20 A As required
12 Slip Ring motor 10kW 1
13 5 pin round 3 phase socket 415V 20A 1
14 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
10 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
4 Test the functionality of completed project
a Dead circuit test b Life circuit test
5 Measure starting and running Amps
LESSON 16
TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
An installation in general will suffer damage
Damage usually occurs on the electric motor control as follows
1 Damage to the main circuit
2 Damage to the control circuit
The cause of the damage
i Overcurrent overload short circuit
ii Leakage current to ground
iii Equipment malfunction
iv The main control circuit
a Trip of main circuit protection devices fire
b Defect of motor terminal such as short circuit fire loose
v The control circuit is not functioning -
a contactor relay relay time overload relay does not work damaged burned
b Loose cable connection disconnected
Detecting and Repairing Damage
Examples of damage are as follows
i Motor does not work
ii Motor function and overload relay trips
iii Motor function but only partially functional control circuit
Methods of detecting damage
Among the known methods necessary to detect damage are as follows
1 Turn off the electricity at the main switch (main switch) in order to avoid any danger during the
work carried out to detect damage
2 Check all the protective gear that controls the motor control main circuit
11 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
3 Make sure the damage function control circuit
4 Check the control circuit according to the schematic circuit diagram of the motor control
5 Check the operation of the control circuit
Note
Use wiring that has been installed on the SYSTEM OF MOTOR CONTROL BOARD by Forward
Reverse control circuit for Star Delta to test and look for damage
SELF-ASSESSMENT QUESTIONS
1 (a) Explain what is meant by the term lsquoback emfrsquo in a motor
(b) Outline the basic differences between series shunt and compound wound dc motors
2 (a) With the aid of diagrams explain how the speed of series shunt and compound-wound motors
may be controlled
(b) A 440V dc shunt-wound motor has a field resistance of 200R and an armature resistance of 06 R
When its speed is 20 rev d second the current drawn from the supply is 122A Calculate its back
emf at this speed If the speed were decreased to 19 revssecond the field flux remaining unchanged
calculate the new back emf and the new armature current
3 A load of 64 kW at 240 V is supplied from the terminals of a shunt-wound dc generator The field
resistance is 180 A Calculate the armature current
4 (a) Explain with the aid of a diagram how a rotating magnetic field may be
(b) What is meant by lsquosynchronous speedrsquo
Calculate the synchronous obtained speed of a 12 pole motor if the supply frequency is 50Hz
5 (a) Explain the action of a synchronous motor
(b) What methods are available to start a synchronous motor Explain with diagrams
6 (a) Explain the action of a cage induction motor
(b) What is meant by the term lsquosliprsquo
Calculate the percentage slip of a six pole induction motor running at 162 revssecond from a 50 Hz
supply
7 Describe with sketches three different ways of starting a single-phase induction motor
12 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
8 Explain with the aid of a sketch the action of a three-phase DOL starter
What are dashpots used for How are remote start and stop buttons connected
9 A I0 kW 240V 50Hz single-phase cage rotor induction motor is 85efficient and has a PF of 068
lagging Calculate the motor current and the value of capacitor required to raise the PF to 093
lagging
10 Calculate the torque developed by an 18 kW four-pole induction motor run at 35 slip from a
50Hz supply
APPENDIX 1
13 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 11
14 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 111
Attachment Reference
httpswwwtlc-directcoukBook621htm
httpwwwstgovmyindexphpms
15 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify each components and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
4 Test the functionality of completed project
1 dead circuit test
2 life circuit
Note Proper earthing should be made
50 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 7 ndash WIRING SYSTEM OF THREE PHASE LIGHTING AND POWER CIRCUIT
51 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
52 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify component and the specification
2 Wire component according to the schematic diagram
3 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting bay Board Perforated metal 180 cm x 180 cm 1
2 k Watt hour meter 415V 60A 1
3 MCCB 415V 60A
4 ELCB RCCB In=60A415 Vac I trip=30mA 1
5 5 pin round Socket and
plug
415Vac 32A 4
6 Single pole MCB 6A 1
7 Triple pole MCB 20A 2
8 Triple pole Main switch 60A 1
9 DOL starter 240Vac 2
10 3 phase induction motor 2hp 415 Vac 1
11 1 phase induction motor 1
12 Metal trunking 30 mm x30 mm As required
13 Self tapping Wood screw 4 mm x 20 mm As required
14 DIN rail 25 mm x 1mm
15 GI steel rigid conduit 20mm As required
16 Flexible conduit 20mm As required
17 End box 20 mm 4
18 Flexible wires 05 mm As required
19 Connectors 10 A As required
Procedures
1 Identify each components and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
4 Test the functionality of completed project
1 dead circuit 2 life circuit test
5 Record the current drawn by the load as connected in star and delta
Note Proper earthing should be made
53 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 8 INSPECTION AND TESTING OF ELECTRICAL INSTALLATION
On completion of a wiring installation a number of tests on the installation have to be conducted to
ascertain that the wiring circuits and connected appliances are safe for use Prior to carrying out the
tests an inspection has to be done The results of the inspectionsupervision and test have to be
presented in Form G (as in Appendix IV) and Form H (as in Appendix V)
To have the test certification as in Form H the following tests shall be conducted
i Continuity Test
ii Insulation Resistance Test
iii Polarity Test
iv Earth Electrode Resistance test and
v Residual Current Device Test
1 Continuity Test
There are 3 main types of continuity tests for the final circuits-
i Protection Conductor Continuity Test
ii Final Ring Circuit Conductor Continuity Test
iii Live and Neutral Conductor Continuity Test
a) Protection Conductor Continuity Test
bull To ascertain that all protection conductors are connected in the correct and effective manner
bull Test equipment ndash Multimeter (Ohm range) or Ohm meter
54 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
bull Test Method
1 1048766 Ensure that the main switch RCD and MCB are open circuited (switched off) and all loads
are disconnected
2 1048766 Connected the test leads as in the Figure 81 The meter reading shall be less than 1 Ω
55 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Final Ring Circuit Conductor Continuity Test
bull To ensure that all conductors around the ring circuit have continuity
bull Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
bull Test Method
1 1048766 Disconnect both the supply source live conductors from the MCB the neutral conductor
from the neutral terminals and the earth conductor from the earth terminal in the distribution
fuse box
2 1048766 Connect the test leads as in the Figure 82 (EE)
3 1048766 Repeat the procedure for (L-L) and (N-N)
4 1048766 The meter reading value shall be less than 1 ohm
56 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Live and Neutral Conductor Continuity Test
a To ensure that each conductor in the circuit has continuity
b Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
2 Test Method
1 1048766 Switch off the Main switch RCD and MCB
2 1048766 Disconnect all loads
3 1048766 Switch on all switches in the circuit
4 1048766 Disconnect the fusesfinal circuit breakers and close the circuit
5 1048766 Carry out the test as shown in Figure 83
6 1048766 The meter reading value shall be less than 1Ω
57 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
58 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
CONTINUITY TEST
Insulation Resistance Test
i Ensure that there is no leakage current between phase conductors phase and neutral conductors and
phase conductor and earth
ii Test the strength of the cable insulation
iii Test Equipment ndash Insulation Resistance Tester operating voltage is 250VDC or 500VDC
iv Test Method
1 1048766 Switch off main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
59 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
4 1048766 Carry out test as in the Table below
5 1048766 Meter reading value shall be less than 1 Megaohm
60 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
61 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Insulation resitance test
62 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
INSULATION RESISTANCE TEST BETWEEN CONDUCTORS AND OPPOSITE POLARITY
Polarity Testi Ensure that each fuse or single pole control and protection device is connected only in the phase
conductor
ii Intermediate contact of Edison screw lamp holder is connected to the phase conductor
iii Ensure that phase neutral and earth conductors at socket outlets are connected at the correct
terminals
iv Test Equipment ndash Multimeter (Ohm range) or Ohm meter
v Test Method
1 1048766 Switch off Main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in Figure 85
63 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
5 1048766 Test switches and single phase control devices at the phase conductors
6 1048766 Test socket outlet connection sources
7 1048766 Test Edison screw lamp holder connections
8 1048766 Meter reading value shall be less than 1 Ω
64 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Polarity test
65 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Earth Electrode Resistance Testi To test the earth electrode resistance
ii To ascertain the suitability of the location of the electrode
iii To ensure that the electrode is not buried within the resistance area of another electrode
iv Test equipment ndash Earth Resistance Tester
v Test method -
1 1048766 Terminal rsquoErsquo is connected to the electrode to be tested (green conductor)
2 1048766 Terminal lsquoPrsquo is connected to the potential spike (yellow conductor) at a distance of 10
meters from the earth electrode
3 1048766 Terminal lsquoCrsquo is connected to the current spike (red conductor) at a distance of 20 meters
from the earth electrode
Earth Electrode Resistance Measurement Method (Figure 86)
This test must be repeated at least three times to ensure that the reading is not affected by interacting
earthing regions
i Record the first reading (Z1) Example Z1 = 10 Ω
ii Move the voltage spike to a distance of 6 meters from the original position Record the second
reading (Z2 ) Example Z2 = 10 Ω
iii Move the voltage spike to a distance of 6 meters from the original position Record the third
reading (Z3) Example Z3 = 10 Ω
66 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Residual Current Device Testi Ensure that the residual current device (RCD) trips within the set time on the occurrence of current
leakage to earth
ii Test Equipment ndash RCD Tester RCCB Tester
iii Test Method 1
1 1048766 Use the Trip Test Button
2 1048766 Press the trip button found on the RCD to determine if it trips or otherwise This test would
not be able to determine the sensitivity of the RCD nor the time taken for it to trip
iv Test Method 2
i 1048766 Use a RCD Tester
ii This equipment is equipped with a 13A plug which can be connected to a 13A socket outlet
Select the RCD sensitivity to be the same as the sensitivity of the RCD to be tested to
determine if the RCD can trip The time to trip shall not exceed 40 mS
iii 1048766 Test method ndash
a) Position the selection switch in accordance with the sensitivity of the RCD used
Example 100 mA 01 A
b) Position the operations switch to lsquoNo Triprsquo (frac12 Rated mA = 50) connect the 3 pin plug to
the 13A socket outlet
67 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
c) Switch on the 13A socket outlet ndash ensure that the P-N and P-E lights light up
This shows that the polarity is correct (Note if both the lights as above do not light up the test cannot
be continued)
d) Press the test button ndash the reading shows less than 200 mS and simultaneously the lsquotestrsquo light lights
up and the P-N and P-E lights do not light up At that instant the RCD will not trip
e) Move the selection switch to 180o (+ve wave) ndash repeat steps (d) and (e) Move the operations
switch to lsquoTriprsquo (Rated mA = 100)
g) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200mS
h) Move the selection switch to 0o (-ve wave)
i) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
j) The above test is repeated until a near correct reading is obtained
k) Record the test results
l) Change the operations switch to lsquoFast Triprsquo and press the test button ndash RCD will trip within a
time not exceeding 40 millisecond
m) Repeat a number of times at 0o or 180o
On completion of a wiring installation a number of tests on the installation have to be conducted to
ascertain that the wiring circuits and connected appliances are safe for use Prior to carrying out the
tests an inspection has to be done the following tests shall be conducted
i Continuity Test
ii Insulation Resistance Test
iii Polarity Test
iv Earth Electrode Resistance test and
v Residual Current Device Test
821 Continuity Test
There are 3 main types of continuity tests for the final circuits-
i Protection Conductor Continuity Test
ii Final Ring Circuit Conductor Continuity Test
68 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
iii Live and Neutral Conductor Continuity Test
a) Protection Conductor Continuity Test
bull To ascertain that all protection conductors are connected in the correct and effective manner
bull Test equipment ndash Multimeter (Ohm range) or Ohm meter
bull Test Method
1 1048766 Ensure that the main switch RCD and MCB are open circuited (switched off) and all loads are
disconnected
2 1048766 Connected the test leads as in the Figure 81
3 1048766 The meter reading shall be less than 1 Ω
Final Ring Circuit Conductor Continuity Test
bull To ensure that all conductors around the ring circuit have continuity
bull Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
bull Test Method
1 1048766 Disconnect both the supply source live conductors from the MCB the neutral conductor
from the neutral terminals and the earth conductor from the earth terminal in the distribution
fuse box
2 1048766 Connect the test leads as in the Figure 82 (EE)
3 1048766 Repeat the procedure for (L-L) and (N-N)
4 1048766 The meter reading value shall be less than 1 ohm Figure 82 - Final Ring Circuit Conductor
Continuity Test Ohm Meter
Disconnect both the supply source cables from mcbfuse
Take readings at earth conductors of both sources and note resistance readings
Live and Neutral Conductor Continuity Test
1 To ensure that each conductor in the circuit has continuity
2 Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
3 Test Method
1 1048766 Switch off the Main switch RCD and MCB
2 1048766 Disconnect all loads
3 1048766 Switch on all switches in the circuit
4 1048766 Disconnect the fusesfinal circuit breakers and close the circuit
5 1048766 Carry out the test as shown in Figure 83
6 1048766 The meter reading value shall be less than 1 ohm Figure 83 - Live and Neutral
Conductor Continuity Test Ohm Meter
Insulation Resistance Test
69 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
i Ensure that there is no leakage current between phase conductors phase and neutral conductors and
phase conductor and earth
ii Test the strength of the cable insulation
iii Test Equipment ndash Insulation Resistance Tester Operating voltage is 250VDC or 500VDC
iv Test Method
1 1048766 Switch off main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in the Table below
5 1048766 Meter reading value shall be less than 1 Megaohm
Polarity Test
i Ensure that each fuse or single pole control and protection device is connected only in the phase
conductor
ii Intermediate contact of Edison screw lamp holder is connected to the phase conductor
iii Ensure that phase neutral and earth conductors at socket outlets are connected at the correct
terminals
iv Test Equipment ndash Multimeter (Ohm range) or Ohm meter
v Test Method
1 1048766 Switch off Main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in Figure 85
5 1048766 Test switches and single phase control devices at the phase conductors
6 1048766 Test socket outlet connection sources
7 1048766 Test Edison screw lamp holder connections
8 1048766 Meter reading value shall be less than 1 Ω
Earth Electrode Resistance Test
i To test the earth electrode resistance
70 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
ii To ascertain the suitability of the location of the electrode
iii To ensure that the electrode is not buried within the resistance area of another electrode
iv Test equipment ndash Earth Resistance Tester
v Test method -
1 1048766 Terminal rsquoErsquo is connected to the electrode to be tested (green conductor)
2 1048766 Terminal lsquoPrsquo is connected to the potential spike (yellow conductor) at a distance of 10
meters from the earth electrode
3 1048766 Terminal lsquoCrsquo is connected to the current spike (red conductor) at a distance of 20 meters
from the earth electrode E P C Electrode 10 meter 10 meter
Figure 86 ndash Earth Electrode Resistance Measurement Test Equipment
Earth Electrode Resistance Measurement Method (Figure 86)
This test must be repeated at least three times to ensure that the reading is not affected by interacting
earthing regions
i Record the first reading (Z1) Example Z1 = 10 Ω
ii Move the voltage spike to a distance of 6 meters from the original position Record the second
reading (Z2) Example Z2 = 10 Ω
iii Move the voltage spike to a distance of 6 meters from the original position Record the third
reading (Z3)
Example Z3 = 10 Ω
Residual Current Device Test
71 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
i Ensure that the residual current device (RCD) trips within the set time on the occurrence of current
leakage to earth
ii Test Equipment ndash RCD Tester RCCB Tester
iii Test Method 1
1 1048766 Use the Trip Test Button
2 1048766 Press the trip button found on the RCD to determine if it trips or otherwise This test would
not be able to determine the sensitivity of the RCD nor the time taken for it to trip
iv Test Method 2
1048766 Use a RCD Tester
This equipment is equipped with a 13A plug which can be connected to a 13A socket outlet Select the
RCD sensitivity to be the same as the sensitivity of the RCD to be tested to determine if the RCD can
trip The time to trip shall not exceed 40 mS
1048766 Test method ndash
a) Position the selection switch in accordance with the sensitivity of the RCD used
Example 100 mA 01 A
b) Position the operations switch to lsquoNo Triprsquo (frac12 Rated mA = 50) connect the 3 pin plug to
the 13A socket outlet
c) Switch on the 13A socket outlet ndash ensure that the P-N and P-E lights light up This shows that
the polarity is correct (Note if both the lights as above do not light up the test cannot be
continued)
d) Press the test button ndash the reading shows less than 200 millisecond and simultaneously the
lsquotestrsquo light lights up and the P-N and P-E lights do not light up At that instant the RCD will
not trip
e) Move the selection switch to 180o (+ve wave) ndash repeat steps (d) and (e) = 100)
f) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
g) Move the selection switch to 0o (-ve wave)
h) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
i) The above test is repeated until a near correct reading is obtained
j) Record the test results
k) Change the operations switch to lsquoFast Triprsquo and press the test button ndash RCD will trip within a
time not exceeding 40 mS
l) Repeat a number of times at 0o or 180o
72 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 9 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (DC)
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
73 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Start stop button 240Vac 5A 2
9 Filament lamp (Bulb ) 240Vac 40W 3
10 Overload Relay 415V 20A 3
11 Three phase induction motor 5 hp 3
12 Single phase step down transformer 2500VA 1
13 Single core PVC insulated Cable 1mm 2 As required
14 Single core PVC insulated Cable 25mm 2 As required
15 DIN rail 35 mm As required
16 PVC type Cable tray 50 mm x 50 mm As required
17 Cable ties 4 ldquo As required
18 Flexible wires 05 mm As required
19 PVC Connectors 5 A amp 20 A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the schematic
diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a optional exercise
i Simple DOL starter
ii Forward reverse DOL starter
iii Forward Reverse Dahlander motor
iv Three motors operated in sequence by DOL starter operated by manual push
button or time delay relay
74 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
a One loop per-cycle
b Continuous operation in a loop
c optional circuit design to represent the same task
v Only one out of three motors to be operated at a time (quiz)
4 Test the functionality of completed project
LESSON 10 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (AC)
75 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 1
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Lamp point 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
76 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
11 Overload Relay 415V 20A 3
12 Three phase induction
motor
5 hp 3
13 Single core PVC insulated
Cable
1mm 2 As required
14 Single core PVC insulated
Cable
25mm 2 As required
15 DIN rail 35 mm As required
16 PVC type Cable tray 50 mm x 50 mm As required
17 Cable ties 4 ldquo As required
18 Flexible wires 05 mm As required
19 PVC Connectors 5 A amp 20 A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the
schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram optional exercise
4 Simple DOL starter
5 Forward reverse DOL starter
6 Test the functionality of completed project
77 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 1
78 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
cm
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Indicating light 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
11 Overload Relay 415V 20A 3
12 Three phase induction motor 5 hp 3
13 Single phase step down
transformer
2500VA 1
14 Single core PVC insulated
Cable
1mm 2 As required
15 Single core PVC insulated
Cable
25mm 2 As required
16 DIN rail 35 mm As required
17 PVC type Cable tray 50 mm x 50 mm As required
18 Cable ties 4 ldquo As required
19 Flexible wires 05 mm As required
20 PVC Connectors 5 A amp 20 A 240 V As required
21 Single pole MCB 6A 240 V 1
22 Single pole MCB 2A 240 V 1
23 Triple pole MCB 20A 415 V 1
24 Mounting board 30 cm x 40 cm x 3
cm
1
25 Relay cw 11 pin socket 10 A 240 Vac 2
26 Time delay relay 10 A 240 Vac 3
27 Triple pole Contactor 20A 240Vac 3
28 Batten type Lamp holder 240Vac 10 A 3
29 Start stop button 240Vac 10A 2
30 Indicating light (Bulb ) 240Vac 25W 3
31 Overload Relay 415V 20A 1
32 Three phase dahlander type
induction motor
5 hp 1
33 Single phase step down
transformer
24024Vac
2500VA
1
79 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
34 Single core PVC insulated
Cable
1mm 2 As required
35 Single core PVC insulated
Cable
25mm 2 As required
36 DIN rail 35 mm As required
37 PVC type Cable tray 50 mm x 50 mm As required
38 Cable ties 4 ldquo As required
39 Flexible wires 075 mm As required
40 PVC Connectors 5 A amp 20 A 240 V As required
41 Terminal block 20A 240Vac As required
Procedures
5 Identify each component according to specification and quantity required from the schematic
diagram attached
6 Test the functionality of each component by using multi-meter or power supply whichever
applicable
7 Wire component according to circuit diagram
8 Three motors operated in sequence by DOL starter operated by manual push button or time
delay relay
a One loop per-cycle
b Continuous operation in a loop
c optional circuit design to represent the same task
d Only one out of three motors to be operated at a time (quiz)
9 Test the functionality of completed project
80 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
BASIC DESIGN INDUSTRIAL MOTOR CONTROL (SEQUENCE CONTROL)
THREE PHASE INDUCTION MOTOR OPERATED IN SEQUENCE BY DIRECT ON LINE
STARTER
LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
81 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
82 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Lcd lamp indicator 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
11 Overload Relay 415V 20A 3
12 Three phase induction motor 5 hp 3
13 Single phase step down transformer 2500VA 1
14 Single core PVC insulated Cable 1mm 2 As required
15 Single core PVC insulated Cable 25mm 2 As required
16 DIN rail 35 mm As required
17 PVC type Cable tray 50 mm x 50 mm As required
18 Cable ties 4 ldquo As required
19 Flexible wires 1 mm Oslash As required
20 PVC Terminal block 10A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the schematic
diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a optional exercise
i Forward Reverse dahlander motor
4 Test the functionality of completed project
83 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
THREE PHASE DAHLANDER TYPE INDUCTION MOTOR OPERATED FORWARD AND
REVERSE OPERATION BY DIRECT ON LINE STARTER
84 ndash 99EASYTECH ENTERPRISE
LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
Introduction
If a motors windings are connected in the star configuration any two phases will be in series across
the supply and hence the line current will be smaller(by 577) than if the windings were connected in
the delta arrangement
Hence larger-type motors with heavy starting currents are first connected in star and then when the
starting currents fall in delta This of course means that all six of the ends of the windings must be
brought to terminations outside the casing (Fig 833)
EZTECH
EZTECH ELECTRICAL INSTALLATION GUIDE
The automatic version of this starter incorporates a timing relay which automatically changes the
connections from star to delta Figs 834 and 835 show the wiring and schematic diagrams for a star
delta starter
Objectives
1 Identify component and the specification
2 Design forward reverse star delta starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
2 ndash 99EASYTECH ENTERPRISE
REV -C
LEGENDMCCB Moulded Case Circuit BreakerTOR Thermal Over Load RelayFOW-C Mains Forward ContactorREV-C Mains Reverse ContactorDC Delta ContactorSC Star ContactorS-SW Mains Selector Switch
SC
V2
W2
U2
DC
V1
W1
U1
TOR
TOR
FOW-C
30A MCCB
TOR
MAIN CIRCUIT FORWARD REVERSE STAR DELTA
RYBN S
-SW
3 PHASEINDUCTION MOTOR
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Relay 10 A 240V 3
5 Triple pole Contactor
6 cw NO NC auxiliary contact
240Vac 20 A 4
7 Overload Relay 415 V 1
8 LED indicator 240vac 5 A 4
9 Start stop button 240Vac 5A 2
10 DIN rail 35 mm As required
11 Flexible wires 1 mm As required
12 Single core PVC insulated
wire
25 mm As required
13 Terminal block 20 A As required
14 Squirrel cage motor 5kW 1
15 5 pin plug and socket 415V 20A 1
16 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
3 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
a Manual star delta
b Manual Forward reverse star delta starter
c Automatic star delta starter
d Automatic Forward reverse star delta starter
4 Test the functionality of completed project
4 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
Objectives
1 Identify component and the specification
2 Design auto transformer starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
5 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Autotransformer starter is used to start a 3 phase induction motor that has a rating between 10 to 15 hp
6 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Autotransformer set 10Kw 415 V 50 Hz 1
5 Triple pole Contactor 240Vac 4
6 Batten type Lamp holder 240 Vac 105 A 4
7 Start stop button 240Vac 10A 4
8 Filament lamp (Bulb ) 240Vac 40W 4
9 DIN rail 35 mm As required
10 Flexible wires 1 mm As required
7 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
11 Single core PVC insulated
wire
25 mm As required
12 Terminal block 20 A As required
13 Squirrel cage motor 10kW 1
14 5 pin plug and socket 415V 20A 1
15 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a open transient autotransformer starter
b close transient autotransformer starter
c Forward reverse autotransformer starter
4 Test the functionality of completed project
8 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
Objectives
1 Identify component and the specification
2 Design rotor resistance starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
9 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Rotor Resistor set 10kW 1
5 Triple pole Contactor 240Vac 20A 4
6 Indicating light 240vac 5 A 4
7 Start stop push button 240Vac 5A 4
8 DIN rail 35 mm As required
9 Flexible wires 1 mm 2 As required
10 Single core PVC insulated wire 25 mm 2 As required
11 Terminal block 20 A As required
12 Slip Ring motor 10kW 1
13 5 pin round 3 phase socket 415V 20A 1
14 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
10 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
4 Test the functionality of completed project
a Dead circuit test b Life circuit test
5 Measure starting and running Amps
LESSON 16
TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
An installation in general will suffer damage
Damage usually occurs on the electric motor control as follows
1 Damage to the main circuit
2 Damage to the control circuit
The cause of the damage
i Overcurrent overload short circuit
ii Leakage current to ground
iii Equipment malfunction
iv The main control circuit
a Trip of main circuit protection devices fire
b Defect of motor terminal such as short circuit fire loose
v The control circuit is not functioning -
a contactor relay relay time overload relay does not work damaged burned
b Loose cable connection disconnected
Detecting and Repairing Damage
Examples of damage are as follows
i Motor does not work
ii Motor function and overload relay trips
iii Motor function but only partially functional control circuit
Methods of detecting damage
Among the known methods necessary to detect damage are as follows
1 Turn off the electricity at the main switch (main switch) in order to avoid any danger during the
work carried out to detect damage
2 Check all the protective gear that controls the motor control main circuit
11 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
3 Make sure the damage function control circuit
4 Check the control circuit according to the schematic circuit diagram of the motor control
5 Check the operation of the control circuit
Note
Use wiring that has been installed on the SYSTEM OF MOTOR CONTROL BOARD by Forward
Reverse control circuit for Star Delta to test and look for damage
SELF-ASSESSMENT QUESTIONS
1 (a) Explain what is meant by the term lsquoback emfrsquo in a motor
(b) Outline the basic differences between series shunt and compound wound dc motors
2 (a) With the aid of diagrams explain how the speed of series shunt and compound-wound motors
may be controlled
(b) A 440V dc shunt-wound motor has a field resistance of 200R and an armature resistance of 06 R
When its speed is 20 rev d second the current drawn from the supply is 122A Calculate its back
emf at this speed If the speed were decreased to 19 revssecond the field flux remaining unchanged
calculate the new back emf and the new armature current
3 A load of 64 kW at 240 V is supplied from the terminals of a shunt-wound dc generator The field
resistance is 180 A Calculate the armature current
4 (a) Explain with the aid of a diagram how a rotating magnetic field may be
(b) What is meant by lsquosynchronous speedrsquo
Calculate the synchronous obtained speed of a 12 pole motor if the supply frequency is 50Hz
5 (a) Explain the action of a synchronous motor
(b) What methods are available to start a synchronous motor Explain with diagrams
6 (a) Explain the action of a cage induction motor
(b) What is meant by the term lsquosliprsquo
Calculate the percentage slip of a six pole induction motor running at 162 revssecond from a 50 Hz
supply
7 Describe with sketches three different ways of starting a single-phase induction motor
12 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
8 Explain with the aid of a sketch the action of a three-phase DOL starter
What are dashpots used for How are remote start and stop buttons connected
9 A I0 kW 240V 50Hz single-phase cage rotor induction motor is 85efficient and has a PF of 068
lagging Calculate the motor current and the value of capacitor required to raise the PF to 093
lagging
10 Calculate the torque developed by an 18 kW four-pole induction motor run at 35 slip from a
50Hz supply
APPENDIX 1
13 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 11
14 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 111
Attachment Reference
httpswwwtlc-directcoukBook621htm
httpwwwstgovmyindexphpms
15 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 7 ndash WIRING SYSTEM OF THREE PHASE LIGHTING AND POWER CIRCUIT
51 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
52 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify component and the specification
2 Wire component according to the schematic diagram
3 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting bay Board Perforated metal 180 cm x 180 cm 1
2 k Watt hour meter 415V 60A 1
3 MCCB 415V 60A
4 ELCB RCCB In=60A415 Vac I trip=30mA 1
5 5 pin round Socket and
plug
415Vac 32A 4
6 Single pole MCB 6A 1
7 Triple pole MCB 20A 2
8 Triple pole Main switch 60A 1
9 DOL starter 240Vac 2
10 3 phase induction motor 2hp 415 Vac 1
11 1 phase induction motor 1
12 Metal trunking 30 mm x30 mm As required
13 Self tapping Wood screw 4 mm x 20 mm As required
14 DIN rail 25 mm x 1mm
15 GI steel rigid conduit 20mm As required
16 Flexible conduit 20mm As required
17 End box 20 mm 4
18 Flexible wires 05 mm As required
19 Connectors 10 A As required
Procedures
1 Identify each components and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
4 Test the functionality of completed project
1 dead circuit 2 life circuit test
5 Record the current drawn by the load as connected in star and delta
Note Proper earthing should be made
53 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 8 INSPECTION AND TESTING OF ELECTRICAL INSTALLATION
On completion of a wiring installation a number of tests on the installation have to be conducted to
ascertain that the wiring circuits and connected appliances are safe for use Prior to carrying out the
tests an inspection has to be done The results of the inspectionsupervision and test have to be
presented in Form G (as in Appendix IV) and Form H (as in Appendix V)
To have the test certification as in Form H the following tests shall be conducted
i Continuity Test
ii Insulation Resistance Test
iii Polarity Test
iv Earth Electrode Resistance test and
v Residual Current Device Test
1 Continuity Test
There are 3 main types of continuity tests for the final circuits-
i Protection Conductor Continuity Test
ii Final Ring Circuit Conductor Continuity Test
iii Live and Neutral Conductor Continuity Test
a) Protection Conductor Continuity Test
bull To ascertain that all protection conductors are connected in the correct and effective manner
bull Test equipment ndash Multimeter (Ohm range) or Ohm meter
54 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
bull Test Method
1 1048766 Ensure that the main switch RCD and MCB are open circuited (switched off) and all loads
are disconnected
2 1048766 Connected the test leads as in the Figure 81 The meter reading shall be less than 1 Ω
55 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Final Ring Circuit Conductor Continuity Test
bull To ensure that all conductors around the ring circuit have continuity
bull Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
bull Test Method
1 1048766 Disconnect both the supply source live conductors from the MCB the neutral conductor
from the neutral terminals and the earth conductor from the earth terminal in the distribution
fuse box
2 1048766 Connect the test leads as in the Figure 82 (EE)
3 1048766 Repeat the procedure for (L-L) and (N-N)
4 1048766 The meter reading value shall be less than 1 ohm
56 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Live and Neutral Conductor Continuity Test
a To ensure that each conductor in the circuit has continuity
b Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
2 Test Method
1 1048766 Switch off the Main switch RCD and MCB
2 1048766 Disconnect all loads
3 1048766 Switch on all switches in the circuit
4 1048766 Disconnect the fusesfinal circuit breakers and close the circuit
5 1048766 Carry out the test as shown in Figure 83
6 1048766 The meter reading value shall be less than 1Ω
57 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
58 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
CONTINUITY TEST
Insulation Resistance Test
i Ensure that there is no leakage current between phase conductors phase and neutral conductors and
phase conductor and earth
ii Test the strength of the cable insulation
iii Test Equipment ndash Insulation Resistance Tester operating voltage is 250VDC or 500VDC
iv Test Method
1 1048766 Switch off main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
59 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
4 1048766 Carry out test as in the Table below
5 1048766 Meter reading value shall be less than 1 Megaohm
60 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
61 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Insulation resitance test
62 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
INSULATION RESISTANCE TEST BETWEEN CONDUCTORS AND OPPOSITE POLARITY
Polarity Testi Ensure that each fuse or single pole control and protection device is connected only in the phase
conductor
ii Intermediate contact of Edison screw lamp holder is connected to the phase conductor
iii Ensure that phase neutral and earth conductors at socket outlets are connected at the correct
terminals
iv Test Equipment ndash Multimeter (Ohm range) or Ohm meter
v Test Method
1 1048766 Switch off Main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in Figure 85
63 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
5 1048766 Test switches and single phase control devices at the phase conductors
6 1048766 Test socket outlet connection sources
7 1048766 Test Edison screw lamp holder connections
8 1048766 Meter reading value shall be less than 1 Ω
64 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Polarity test
65 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Earth Electrode Resistance Testi To test the earth electrode resistance
ii To ascertain the suitability of the location of the electrode
iii To ensure that the electrode is not buried within the resistance area of another electrode
iv Test equipment ndash Earth Resistance Tester
v Test method -
1 1048766 Terminal rsquoErsquo is connected to the electrode to be tested (green conductor)
2 1048766 Terminal lsquoPrsquo is connected to the potential spike (yellow conductor) at a distance of 10
meters from the earth electrode
3 1048766 Terminal lsquoCrsquo is connected to the current spike (red conductor) at a distance of 20 meters
from the earth electrode
Earth Electrode Resistance Measurement Method (Figure 86)
This test must be repeated at least three times to ensure that the reading is not affected by interacting
earthing regions
i Record the first reading (Z1) Example Z1 = 10 Ω
ii Move the voltage spike to a distance of 6 meters from the original position Record the second
reading (Z2 ) Example Z2 = 10 Ω
iii Move the voltage spike to a distance of 6 meters from the original position Record the third
reading (Z3) Example Z3 = 10 Ω
66 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Residual Current Device Testi Ensure that the residual current device (RCD) trips within the set time on the occurrence of current
leakage to earth
ii Test Equipment ndash RCD Tester RCCB Tester
iii Test Method 1
1 1048766 Use the Trip Test Button
2 1048766 Press the trip button found on the RCD to determine if it trips or otherwise This test would
not be able to determine the sensitivity of the RCD nor the time taken for it to trip
iv Test Method 2
i 1048766 Use a RCD Tester
ii This equipment is equipped with a 13A plug which can be connected to a 13A socket outlet
Select the RCD sensitivity to be the same as the sensitivity of the RCD to be tested to
determine if the RCD can trip The time to trip shall not exceed 40 mS
iii 1048766 Test method ndash
a) Position the selection switch in accordance with the sensitivity of the RCD used
Example 100 mA 01 A
b) Position the operations switch to lsquoNo Triprsquo (frac12 Rated mA = 50) connect the 3 pin plug to
the 13A socket outlet
67 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
c) Switch on the 13A socket outlet ndash ensure that the P-N and P-E lights light up
This shows that the polarity is correct (Note if both the lights as above do not light up the test cannot
be continued)
d) Press the test button ndash the reading shows less than 200 mS and simultaneously the lsquotestrsquo light lights
up and the P-N and P-E lights do not light up At that instant the RCD will not trip
e) Move the selection switch to 180o (+ve wave) ndash repeat steps (d) and (e) Move the operations
switch to lsquoTriprsquo (Rated mA = 100)
g) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200mS
h) Move the selection switch to 0o (-ve wave)
i) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
j) The above test is repeated until a near correct reading is obtained
k) Record the test results
l) Change the operations switch to lsquoFast Triprsquo and press the test button ndash RCD will trip within a
time not exceeding 40 millisecond
m) Repeat a number of times at 0o or 180o
On completion of a wiring installation a number of tests on the installation have to be conducted to
ascertain that the wiring circuits and connected appliances are safe for use Prior to carrying out the
tests an inspection has to be done the following tests shall be conducted
i Continuity Test
ii Insulation Resistance Test
iii Polarity Test
iv Earth Electrode Resistance test and
v Residual Current Device Test
821 Continuity Test
There are 3 main types of continuity tests for the final circuits-
i Protection Conductor Continuity Test
ii Final Ring Circuit Conductor Continuity Test
68 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
iii Live and Neutral Conductor Continuity Test
a) Protection Conductor Continuity Test
bull To ascertain that all protection conductors are connected in the correct and effective manner
bull Test equipment ndash Multimeter (Ohm range) or Ohm meter
bull Test Method
1 1048766 Ensure that the main switch RCD and MCB are open circuited (switched off) and all loads are
disconnected
2 1048766 Connected the test leads as in the Figure 81
3 1048766 The meter reading shall be less than 1 Ω
Final Ring Circuit Conductor Continuity Test
bull To ensure that all conductors around the ring circuit have continuity
bull Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
bull Test Method
1 1048766 Disconnect both the supply source live conductors from the MCB the neutral conductor
from the neutral terminals and the earth conductor from the earth terminal in the distribution
fuse box
2 1048766 Connect the test leads as in the Figure 82 (EE)
3 1048766 Repeat the procedure for (L-L) and (N-N)
4 1048766 The meter reading value shall be less than 1 ohm Figure 82 - Final Ring Circuit Conductor
Continuity Test Ohm Meter
Disconnect both the supply source cables from mcbfuse
Take readings at earth conductors of both sources and note resistance readings
Live and Neutral Conductor Continuity Test
1 To ensure that each conductor in the circuit has continuity
2 Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
3 Test Method
1 1048766 Switch off the Main switch RCD and MCB
2 1048766 Disconnect all loads
3 1048766 Switch on all switches in the circuit
4 1048766 Disconnect the fusesfinal circuit breakers and close the circuit
5 1048766 Carry out the test as shown in Figure 83
6 1048766 The meter reading value shall be less than 1 ohm Figure 83 - Live and Neutral
Conductor Continuity Test Ohm Meter
Insulation Resistance Test
69 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
i Ensure that there is no leakage current between phase conductors phase and neutral conductors and
phase conductor and earth
ii Test the strength of the cable insulation
iii Test Equipment ndash Insulation Resistance Tester Operating voltage is 250VDC or 500VDC
iv Test Method
1 1048766 Switch off main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in the Table below
5 1048766 Meter reading value shall be less than 1 Megaohm
Polarity Test
i Ensure that each fuse or single pole control and protection device is connected only in the phase
conductor
ii Intermediate contact of Edison screw lamp holder is connected to the phase conductor
iii Ensure that phase neutral and earth conductors at socket outlets are connected at the correct
terminals
iv Test Equipment ndash Multimeter (Ohm range) or Ohm meter
v Test Method
1 1048766 Switch off Main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in Figure 85
5 1048766 Test switches and single phase control devices at the phase conductors
6 1048766 Test socket outlet connection sources
7 1048766 Test Edison screw lamp holder connections
8 1048766 Meter reading value shall be less than 1 Ω
Earth Electrode Resistance Test
i To test the earth electrode resistance
70 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
ii To ascertain the suitability of the location of the electrode
iii To ensure that the electrode is not buried within the resistance area of another electrode
iv Test equipment ndash Earth Resistance Tester
v Test method -
1 1048766 Terminal rsquoErsquo is connected to the electrode to be tested (green conductor)
2 1048766 Terminal lsquoPrsquo is connected to the potential spike (yellow conductor) at a distance of 10
meters from the earth electrode
3 1048766 Terminal lsquoCrsquo is connected to the current spike (red conductor) at a distance of 20 meters
from the earth electrode E P C Electrode 10 meter 10 meter
Figure 86 ndash Earth Electrode Resistance Measurement Test Equipment
Earth Electrode Resistance Measurement Method (Figure 86)
This test must be repeated at least three times to ensure that the reading is not affected by interacting
earthing regions
i Record the first reading (Z1) Example Z1 = 10 Ω
ii Move the voltage spike to a distance of 6 meters from the original position Record the second
reading (Z2) Example Z2 = 10 Ω
iii Move the voltage spike to a distance of 6 meters from the original position Record the third
reading (Z3)
Example Z3 = 10 Ω
Residual Current Device Test
71 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
i Ensure that the residual current device (RCD) trips within the set time on the occurrence of current
leakage to earth
ii Test Equipment ndash RCD Tester RCCB Tester
iii Test Method 1
1 1048766 Use the Trip Test Button
2 1048766 Press the trip button found on the RCD to determine if it trips or otherwise This test would
not be able to determine the sensitivity of the RCD nor the time taken for it to trip
iv Test Method 2
1048766 Use a RCD Tester
This equipment is equipped with a 13A plug which can be connected to a 13A socket outlet Select the
RCD sensitivity to be the same as the sensitivity of the RCD to be tested to determine if the RCD can
trip The time to trip shall not exceed 40 mS
1048766 Test method ndash
a) Position the selection switch in accordance with the sensitivity of the RCD used
Example 100 mA 01 A
b) Position the operations switch to lsquoNo Triprsquo (frac12 Rated mA = 50) connect the 3 pin plug to
the 13A socket outlet
c) Switch on the 13A socket outlet ndash ensure that the P-N and P-E lights light up This shows that
the polarity is correct (Note if both the lights as above do not light up the test cannot be
continued)
d) Press the test button ndash the reading shows less than 200 millisecond and simultaneously the
lsquotestrsquo light lights up and the P-N and P-E lights do not light up At that instant the RCD will
not trip
e) Move the selection switch to 180o (+ve wave) ndash repeat steps (d) and (e) = 100)
f) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
g) Move the selection switch to 0o (-ve wave)
h) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
i) The above test is repeated until a near correct reading is obtained
j) Record the test results
k) Change the operations switch to lsquoFast Triprsquo and press the test button ndash RCD will trip within a
time not exceeding 40 mS
l) Repeat a number of times at 0o or 180o
72 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 9 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (DC)
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
73 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Start stop button 240Vac 5A 2
9 Filament lamp (Bulb ) 240Vac 40W 3
10 Overload Relay 415V 20A 3
11 Three phase induction motor 5 hp 3
12 Single phase step down transformer 2500VA 1
13 Single core PVC insulated Cable 1mm 2 As required
14 Single core PVC insulated Cable 25mm 2 As required
15 DIN rail 35 mm As required
16 PVC type Cable tray 50 mm x 50 mm As required
17 Cable ties 4 ldquo As required
18 Flexible wires 05 mm As required
19 PVC Connectors 5 A amp 20 A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the schematic
diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a optional exercise
i Simple DOL starter
ii Forward reverse DOL starter
iii Forward Reverse Dahlander motor
iv Three motors operated in sequence by DOL starter operated by manual push
button or time delay relay
74 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
a One loop per-cycle
b Continuous operation in a loop
c optional circuit design to represent the same task
v Only one out of three motors to be operated at a time (quiz)
4 Test the functionality of completed project
LESSON 10 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (AC)
75 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 1
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Lamp point 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
76 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
11 Overload Relay 415V 20A 3
12 Three phase induction
motor
5 hp 3
13 Single core PVC insulated
Cable
1mm 2 As required
14 Single core PVC insulated
Cable
25mm 2 As required
15 DIN rail 35 mm As required
16 PVC type Cable tray 50 mm x 50 mm As required
17 Cable ties 4 ldquo As required
18 Flexible wires 05 mm As required
19 PVC Connectors 5 A amp 20 A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the
schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram optional exercise
4 Simple DOL starter
5 Forward reverse DOL starter
6 Test the functionality of completed project
77 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 1
78 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
cm
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Indicating light 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
11 Overload Relay 415V 20A 3
12 Three phase induction motor 5 hp 3
13 Single phase step down
transformer
2500VA 1
14 Single core PVC insulated
Cable
1mm 2 As required
15 Single core PVC insulated
Cable
25mm 2 As required
16 DIN rail 35 mm As required
17 PVC type Cable tray 50 mm x 50 mm As required
18 Cable ties 4 ldquo As required
19 Flexible wires 05 mm As required
20 PVC Connectors 5 A amp 20 A 240 V As required
21 Single pole MCB 6A 240 V 1
22 Single pole MCB 2A 240 V 1
23 Triple pole MCB 20A 415 V 1
24 Mounting board 30 cm x 40 cm x 3
cm
1
25 Relay cw 11 pin socket 10 A 240 Vac 2
26 Time delay relay 10 A 240 Vac 3
27 Triple pole Contactor 20A 240Vac 3
28 Batten type Lamp holder 240Vac 10 A 3
29 Start stop button 240Vac 10A 2
30 Indicating light (Bulb ) 240Vac 25W 3
31 Overload Relay 415V 20A 1
32 Three phase dahlander type
induction motor
5 hp 1
33 Single phase step down
transformer
24024Vac
2500VA
1
79 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
34 Single core PVC insulated
Cable
1mm 2 As required
35 Single core PVC insulated
Cable
25mm 2 As required
36 DIN rail 35 mm As required
37 PVC type Cable tray 50 mm x 50 mm As required
38 Cable ties 4 ldquo As required
39 Flexible wires 075 mm As required
40 PVC Connectors 5 A amp 20 A 240 V As required
41 Terminal block 20A 240Vac As required
Procedures
5 Identify each component according to specification and quantity required from the schematic
diagram attached
6 Test the functionality of each component by using multi-meter or power supply whichever
applicable
7 Wire component according to circuit diagram
8 Three motors operated in sequence by DOL starter operated by manual push button or time
delay relay
a One loop per-cycle
b Continuous operation in a loop
c optional circuit design to represent the same task
d Only one out of three motors to be operated at a time (quiz)
9 Test the functionality of completed project
80 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
BASIC DESIGN INDUSTRIAL MOTOR CONTROL (SEQUENCE CONTROL)
THREE PHASE INDUCTION MOTOR OPERATED IN SEQUENCE BY DIRECT ON LINE
STARTER
LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
81 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
82 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Lcd lamp indicator 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
11 Overload Relay 415V 20A 3
12 Three phase induction motor 5 hp 3
13 Single phase step down transformer 2500VA 1
14 Single core PVC insulated Cable 1mm 2 As required
15 Single core PVC insulated Cable 25mm 2 As required
16 DIN rail 35 mm As required
17 PVC type Cable tray 50 mm x 50 mm As required
18 Cable ties 4 ldquo As required
19 Flexible wires 1 mm Oslash As required
20 PVC Terminal block 10A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the schematic
diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a optional exercise
i Forward Reverse dahlander motor
4 Test the functionality of completed project
83 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
THREE PHASE DAHLANDER TYPE INDUCTION MOTOR OPERATED FORWARD AND
REVERSE OPERATION BY DIRECT ON LINE STARTER
84 ndash 99EASYTECH ENTERPRISE
LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
Introduction
If a motors windings are connected in the star configuration any two phases will be in series across
the supply and hence the line current will be smaller(by 577) than if the windings were connected in
the delta arrangement
Hence larger-type motors with heavy starting currents are first connected in star and then when the
starting currents fall in delta This of course means that all six of the ends of the windings must be
brought to terminations outside the casing (Fig 833)
EZTECH
EZTECH ELECTRICAL INSTALLATION GUIDE
The automatic version of this starter incorporates a timing relay which automatically changes the
connections from star to delta Figs 834 and 835 show the wiring and schematic diagrams for a star
delta starter
Objectives
1 Identify component and the specification
2 Design forward reverse star delta starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
2 ndash 99EASYTECH ENTERPRISE
REV -C
LEGENDMCCB Moulded Case Circuit BreakerTOR Thermal Over Load RelayFOW-C Mains Forward ContactorREV-C Mains Reverse ContactorDC Delta ContactorSC Star ContactorS-SW Mains Selector Switch
SC
V2
W2
U2
DC
V1
W1
U1
TOR
TOR
FOW-C
30A MCCB
TOR
MAIN CIRCUIT FORWARD REVERSE STAR DELTA
RYBN S
-SW
3 PHASEINDUCTION MOTOR
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Relay 10 A 240V 3
5 Triple pole Contactor
6 cw NO NC auxiliary contact
240Vac 20 A 4
7 Overload Relay 415 V 1
8 LED indicator 240vac 5 A 4
9 Start stop button 240Vac 5A 2
10 DIN rail 35 mm As required
11 Flexible wires 1 mm As required
12 Single core PVC insulated
wire
25 mm As required
13 Terminal block 20 A As required
14 Squirrel cage motor 5kW 1
15 5 pin plug and socket 415V 20A 1
16 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
3 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
a Manual star delta
b Manual Forward reverse star delta starter
c Automatic star delta starter
d Automatic Forward reverse star delta starter
4 Test the functionality of completed project
4 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
Objectives
1 Identify component and the specification
2 Design auto transformer starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
5 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Autotransformer starter is used to start a 3 phase induction motor that has a rating between 10 to 15 hp
6 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Autotransformer set 10Kw 415 V 50 Hz 1
5 Triple pole Contactor 240Vac 4
6 Batten type Lamp holder 240 Vac 105 A 4
7 Start stop button 240Vac 10A 4
8 Filament lamp (Bulb ) 240Vac 40W 4
9 DIN rail 35 mm As required
10 Flexible wires 1 mm As required
7 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
11 Single core PVC insulated
wire
25 mm As required
12 Terminal block 20 A As required
13 Squirrel cage motor 10kW 1
14 5 pin plug and socket 415V 20A 1
15 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a open transient autotransformer starter
b close transient autotransformer starter
c Forward reverse autotransformer starter
4 Test the functionality of completed project
8 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
Objectives
1 Identify component and the specification
2 Design rotor resistance starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
9 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Rotor Resistor set 10kW 1
5 Triple pole Contactor 240Vac 20A 4
6 Indicating light 240vac 5 A 4
7 Start stop push button 240Vac 5A 4
8 DIN rail 35 mm As required
9 Flexible wires 1 mm 2 As required
10 Single core PVC insulated wire 25 mm 2 As required
11 Terminal block 20 A As required
12 Slip Ring motor 10kW 1
13 5 pin round 3 phase socket 415V 20A 1
14 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
10 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
4 Test the functionality of completed project
a Dead circuit test b Life circuit test
5 Measure starting and running Amps
LESSON 16
TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
An installation in general will suffer damage
Damage usually occurs on the electric motor control as follows
1 Damage to the main circuit
2 Damage to the control circuit
The cause of the damage
i Overcurrent overload short circuit
ii Leakage current to ground
iii Equipment malfunction
iv The main control circuit
a Trip of main circuit protection devices fire
b Defect of motor terminal such as short circuit fire loose
v The control circuit is not functioning -
a contactor relay relay time overload relay does not work damaged burned
b Loose cable connection disconnected
Detecting and Repairing Damage
Examples of damage are as follows
i Motor does not work
ii Motor function and overload relay trips
iii Motor function but only partially functional control circuit
Methods of detecting damage
Among the known methods necessary to detect damage are as follows
1 Turn off the electricity at the main switch (main switch) in order to avoid any danger during the
work carried out to detect damage
2 Check all the protective gear that controls the motor control main circuit
11 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
3 Make sure the damage function control circuit
4 Check the control circuit according to the schematic circuit diagram of the motor control
5 Check the operation of the control circuit
Note
Use wiring that has been installed on the SYSTEM OF MOTOR CONTROL BOARD by Forward
Reverse control circuit for Star Delta to test and look for damage
SELF-ASSESSMENT QUESTIONS
1 (a) Explain what is meant by the term lsquoback emfrsquo in a motor
(b) Outline the basic differences between series shunt and compound wound dc motors
2 (a) With the aid of diagrams explain how the speed of series shunt and compound-wound motors
may be controlled
(b) A 440V dc shunt-wound motor has a field resistance of 200R and an armature resistance of 06 R
When its speed is 20 rev d second the current drawn from the supply is 122A Calculate its back
emf at this speed If the speed were decreased to 19 revssecond the field flux remaining unchanged
calculate the new back emf and the new armature current
3 A load of 64 kW at 240 V is supplied from the terminals of a shunt-wound dc generator The field
resistance is 180 A Calculate the armature current
4 (a) Explain with the aid of a diagram how a rotating magnetic field may be
(b) What is meant by lsquosynchronous speedrsquo
Calculate the synchronous obtained speed of a 12 pole motor if the supply frequency is 50Hz
5 (a) Explain the action of a synchronous motor
(b) What methods are available to start a synchronous motor Explain with diagrams
6 (a) Explain the action of a cage induction motor
(b) What is meant by the term lsquosliprsquo
Calculate the percentage slip of a six pole induction motor running at 162 revssecond from a 50 Hz
supply
7 Describe with sketches three different ways of starting a single-phase induction motor
12 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
8 Explain with the aid of a sketch the action of a three-phase DOL starter
What are dashpots used for How are remote start and stop buttons connected
9 A I0 kW 240V 50Hz single-phase cage rotor induction motor is 85efficient and has a PF of 068
lagging Calculate the motor current and the value of capacitor required to raise the PF to 093
lagging
10 Calculate the torque developed by an 18 kW four-pole induction motor run at 35 slip from a
50Hz supply
APPENDIX 1
13 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 11
14 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 111
Attachment Reference
httpswwwtlc-directcoukBook621htm
httpwwwstgovmyindexphpms
15 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
52 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify component and the specification
2 Wire component according to the schematic diagram
3 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting bay Board Perforated metal 180 cm x 180 cm 1
2 k Watt hour meter 415V 60A 1
3 MCCB 415V 60A
4 ELCB RCCB In=60A415 Vac I trip=30mA 1
5 5 pin round Socket and
plug
415Vac 32A 4
6 Single pole MCB 6A 1
7 Triple pole MCB 20A 2
8 Triple pole Main switch 60A 1
9 DOL starter 240Vac 2
10 3 phase induction motor 2hp 415 Vac 1
11 1 phase induction motor 1
12 Metal trunking 30 mm x30 mm As required
13 Self tapping Wood screw 4 mm x 20 mm As required
14 DIN rail 25 mm x 1mm
15 GI steel rigid conduit 20mm As required
16 Flexible conduit 20mm As required
17 End box 20 mm 4
18 Flexible wires 05 mm As required
19 Connectors 10 A As required
Procedures
1 Identify each components and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
4 Test the functionality of completed project
1 dead circuit 2 life circuit test
5 Record the current drawn by the load as connected in star and delta
Note Proper earthing should be made
53 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 8 INSPECTION AND TESTING OF ELECTRICAL INSTALLATION
On completion of a wiring installation a number of tests on the installation have to be conducted to
ascertain that the wiring circuits and connected appliances are safe for use Prior to carrying out the
tests an inspection has to be done The results of the inspectionsupervision and test have to be
presented in Form G (as in Appendix IV) and Form H (as in Appendix V)
To have the test certification as in Form H the following tests shall be conducted
i Continuity Test
ii Insulation Resistance Test
iii Polarity Test
iv Earth Electrode Resistance test and
v Residual Current Device Test
1 Continuity Test
There are 3 main types of continuity tests for the final circuits-
i Protection Conductor Continuity Test
ii Final Ring Circuit Conductor Continuity Test
iii Live and Neutral Conductor Continuity Test
a) Protection Conductor Continuity Test
bull To ascertain that all protection conductors are connected in the correct and effective manner
bull Test equipment ndash Multimeter (Ohm range) or Ohm meter
54 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
bull Test Method
1 1048766 Ensure that the main switch RCD and MCB are open circuited (switched off) and all loads
are disconnected
2 1048766 Connected the test leads as in the Figure 81 The meter reading shall be less than 1 Ω
55 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Final Ring Circuit Conductor Continuity Test
bull To ensure that all conductors around the ring circuit have continuity
bull Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
bull Test Method
1 1048766 Disconnect both the supply source live conductors from the MCB the neutral conductor
from the neutral terminals and the earth conductor from the earth terminal in the distribution
fuse box
2 1048766 Connect the test leads as in the Figure 82 (EE)
3 1048766 Repeat the procedure for (L-L) and (N-N)
4 1048766 The meter reading value shall be less than 1 ohm
56 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Live and Neutral Conductor Continuity Test
a To ensure that each conductor in the circuit has continuity
b Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
2 Test Method
1 1048766 Switch off the Main switch RCD and MCB
2 1048766 Disconnect all loads
3 1048766 Switch on all switches in the circuit
4 1048766 Disconnect the fusesfinal circuit breakers and close the circuit
5 1048766 Carry out the test as shown in Figure 83
6 1048766 The meter reading value shall be less than 1Ω
57 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
58 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
CONTINUITY TEST
Insulation Resistance Test
i Ensure that there is no leakage current between phase conductors phase and neutral conductors and
phase conductor and earth
ii Test the strength of the cable insulation
iii Test Equipment ndash Insulation Resistance Tester operating voltage is 250VDC or 500VDC
iv Test Method
1 1048766 Switch off main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
59 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
4 1048766 Carry out test as in the Table below
5 1048766 Meter reading value shall be less than 1 Megaohm
60 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
61 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Insulation resitance test
62 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
INSULATION RESISTANCE TEST BETWEEN CONDUCTORS AND OPPOSITE POLARITY
Polarity Testi Ensure that each fuse or single pole control and protection device is connected only in the phase
conductor
ii Intermediate contact of Edison screw lamp holder is connected to the phase conductor
iii Ensure that phase neutral and earth conductors at socket outlets are connected at the correct
terminals
iv Test Equipment ndash Multimeter (Ohm range) or Ohm meter
v Test Method
1 1048766 Switch off Main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in Figure 85
63 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
5 1048766 Test switches and single phase control devices at the phase conductors
6 1048766 Test socket outlet connection sources
7 1048766 Test Edison screw lamp holder connections
8 1048766 Meter reading value shall be less than 1 Ω
64 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Polarity test
65 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Earth Electrode Resistance Testi To test the earth electrode resistance
ii To ascertain the suitability of the location of the electrode
iii To ensure that the electrode is not buried within the resistance area of another electrode
iv Test equipment ndash Earth Resistance Tester
v Test method -
1 1048766 Terminal rsquoErsquo is connected to the electrode to be tested (green conductor)
2 1048766 Terminal lsquoPrsquo is connected to the potential spike (yellow conductor) at a distance of 10
meters from the earth electrode
3 1048766 Terminal lsquoCrsquo is connected to the current spike (red conductor) at a distance of 20 meters
from the earth electrode
Earth Electrode Resistance Measurement Method (Figure 86)
This test must be repeated at least three times to ensure that the reading is not affected by interacting
earthing regions
i Record the first reading (Z1) Example Z1 = 10 Ω
ii Move the voltage spike to a distance of 6 meters from the original position Record the second
reading (Z2 ) Example Z2 = 10 Ω
iii Move the voltage spike to a distance of 6 meters from the original position Record the third
reading (Z3) Example Z3 = 10 Ω
66 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Residual Current Device Testi Ensure that the residual current device (RCD) trips within the set time on the occurrence of current
leakage to earth
ii Test Equipment ndash RCD Tester RCCB Tester
iii Test Method 1
1 1048766 Use the Trip Test Button
2 1048766 Press the trip button found on the RCD to determine if it trips or otherwise This test would
not be able to determine the sensitivity of the RCD nor the time taken for it to trip
iv Test Method 2
i 1048766 Use a RCD Tester
ii This equipment is equipped with a 13A plug which can be connected to a 13A socket outlet
Select the RCD sensitivity to be the same as the sensitivity of the RCD to be tested to
determine if the RCD can trip The time to trip shall not exceed 40 mS
iii 1048766 Test method ndash
a) Position the selection switch in accordance with the sensitivity of the RCD used
Example 100 mA 01 A
b) Position the operations switch to lsquoNo Triprsquo (frac12 Rated mA = 50) connect the 3 pin plug to
the 13A socket outlet
67 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
c) Switch on the 13A socket outlet ndash ensure that the P-N and P-E lights light up
This shows that the polarity is correct (Note if both the lights as above do not light up the test cannot
be continued)
d) Press the test button ndash the reading shows less than 200 mS and simultaneously the lsquotestrsquo light lights
up and the P-N and P-E lights do not light up At that instant the RCD will not trip
e) Move the selection switch to 180o (+ve wave) ndash repeat steps (d) and (e) Move the operations
switch to lsquoTriprsquo (Rated mA = 100)
g) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200mS
h) Move the selection switch to 0o (-ve wave)
i) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
j) The above test is repeated until a near correct reading is obtained
k) Record the test results
l) Change the operations switch to lsquoFast Triprsquo and press the test button ndash RCD will trip within a
time not exceeding 40 millisecond
m) Repeat a number of times at 0o or 180o
On completion of a wiring installation a number of tests on the installation have to be conducted to
ascertain that the wiring circuits and connected appliances are safe for use Prior to carrying out the
tests an inspection has to be done the following tests shall be conducted
i Continuity Test
ii Insulation Resistance Test
iii Polarity Test
iv Earth Electrode Resistance test and
v Residual Current Device Test
821 Continuity Test
There are 3 main types of continuity tests for the final circuits-
i Protection Conductor Continuity Test
ii Final Ring Circuit Conductor Continuity Test
68 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
iii Live and Neutral Conductor Continuity Test
a) Protection Conductor Continuity Test
bull To ascertain that all protection conductors are connected in the correct and effective manner
bull Test equipment ndash Multimeter (Ohm range) or Ohm meter
bull Test Method
1 1048766 Ensure that the main switch RCD and MCB are open circuited (switched off) and all loads are
disconnected
2 1048766 Connected the test leads as in the Figure 81
3 1048766 The meter reading shall be less than 1 Ω
Final Ring Circuit Conductor Continuity Test
bull To ensure that all conductors around the ring circuit have continuity
bull Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
bull Test Method
1 1048766 Disconnect both the supply source live conductors from the MCB the neutral conductor
from the neutral terminals and the earth conductor from the earth terminal in the distribution
fuse box
2 1048766 Connect the test leads as in the Figure 82 (EE)
3 1048766 Repeat the procedure for (L-L) and (N-N)
4 1048766 The meter reading value shall be less than 1 ohm Figure 82 - Final Ring Circuit Conductor
Continuity Test Ohm Meter
Disconnect both the supply source cables from mcbfuse
Take readings at earth conductors of both sources and note resistance readings
Live and Neutral Conductor Continuity Test
1 To ensure that each conductor in the circuit has continuity
2 Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
3 Test Method
1 1048766 Switch off the Main switch RCD and MCB
2 1048766 Disconnect all loads
3 1048766 Switch on all switches in the circuit
4 1048766 Disconnect the fusesfinal circuit breakers and close the circuit
5 1048766 Carry out the test as shown in Figure 83
6 1048766 The meter reading value shall be less than 1 ohm Figure 83 - Live and Neutral
Conductor Continuity Test Ohm Meter
Insulation Resistance Test
69 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
i Ensure that there is no leakage current between phase conductors phase and neutral conductors and
phase conductor and earth
ii Test the strength of the cable insulation
iii Test Equipment ndash Insulation Resistance Tester Operating voltage is 250VDC or 500VDC
iv Test Method
1 1048766 Switch off main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in the Table below
5 1048766 Meter reading value shall be less than 1 Megaohm
Polarity Test
i Ensure that each fuse or single pole control and protection device is connected only in the phase
conductor
ii Intermediate contact of Edison screw lamp holder is connected to the phase conductor
iii Ensure that phase neutral and earth conductors at socket outlets are connected at the correct
terminals
iv Test Equipment ndash Multimeter (Ohm range) or Ohm meter
v Test Method
1 1048766 Switch off Main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in Figure 85
5 1048766 Test switches and single phase control devices at the phase conductors
6 1048766 Test socket outlet connection sources
7 1048766 Test Edison screw lamp holder connections
8 1048766 Meter reading value shall be less than 1 Ω
Earth Electrode Resistance Test
i To test the earth electrode resistance
70 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
ii To ascertain the suitability of the location of the electrode
iii To ensure that the electrode is not buried within the resistance area of another electrode
iv Test equipment ndash Earth Resistance Tester
v Test method -
1 1048766 Terminal rsquoErsquo is connected to the electrode to be tested (green conductor)
2 1048766 Terminal lsquoPrsquo is connected to the potential spike (yellow conductor) at a distance of 10
meters from the earth electrode
3 1048766 Terminal lsquoCrsquo is connected to the current spike (red conductor) at a distance of 20 meters
from the earth electrode E P C Electrode 10 meter 10 meter
Figure 86 ndash Earth Electrode Resistance Measurement Test Equipment
Earth Electrode Resistance Measurement Method (Figure 86)
This test must be repeated at least three times to ensure that the reading is not affected by interacting
earthing regions
i Record the first reading (Z1) Example Z1 = 10 Ω
ii Move the voltage spike to a distance of 6 meters from the original position Record the second
reading (Z2) Example Z2 = 10 Ω
iii Move the voltage spike to a distance of 6 meters from the original position Record the third
reading (Z3)
Example Z3 = 10 Ω
Residual Current Device Test
71 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
i Ensure that the residual current device (RCD) trips within the set time on the occurrence of current
leakage to earth
ii Test Equipment ndash RCD Tester RCCB Tester
iii Test Method 1
1 1048766 Use the Trip Test Button
2 1048766 Press the trip button found on the RCD to determine if it trips or otherwise This test would
not be able to determine the sensitivity of the RCD nor the time taken for it to trip
iv Test Method 2
1048766 Use a RCD Tester
This equipment is equipped with a 13A plug which can be connected to a 13A socket outlet Select the
RCD sensitivity to be the same as the sensitivity of the RCD to be tested to determine if the RCD can
trip The time to trip shall not exceed 40 mS
1048766 Test method ndash
a) Position the selection switch in accordance with the sensitivity of the RCD used
Example 100 mA 01 A
b) Position the operations switch to lsquoNo Triprsquo (frac12 Rated mA = 50) connect the 3 pin plug to
the 13A socket outlet
c) Switch on the 13A socket outlet ndash ensure that the P-N and P-E lights light up This shows that
the polarity is correct (Note if both the lights as above do not light up the test cannot be
continued)
d) Press the test button ndash the reading shows less than 200 millisecond and simultaneously the
lsquotestrsquo light lights up and the P-N and P-E lights do not light up At that instant the RCD will
not trip
e) Move the selection switch to 180o (+ve wave) ndash repeat steps (d) and (e) = 100)
f) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
g) Move the selection switch to 0o (-ve wave)
h) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
i) The above test is repeated until a near correct reading is obtained
j) Record the test results
k) Change the operations switch to lsquoFast Triprsquo and press the test button ndash RCD will trip within a
time not exceeding 40 mS
l) Repeat a number of times at 0o or 180o
72 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 9 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (DC)
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
73 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Start stop button 240Vac 5A 2
9 Filament lamp (Bulb ) 240Vac 40W 3
10 Overload Relay 415V 20A 3
11 Three phase induction motor 5 hp 3
12 Single phase step down transformer 2500VA 1
13 Single core PVC insulated Cable 1mm 2 As required
14 Single core PVC insulated Cable 25mm 2 As required
15 DIN rail 35 mm As required
16 PVC type Cable tray 50 mm x 50 mm As required
17 Cable ties 4 ldquo As required
18 Flexible wires 05 mm As required
19 PVC Connectors 5 A amp 20 A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the schematic
diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a optional exercise
i Simple DOL starter
ii Forward reverse DOL starter
iii Forward Reverse Dahlander motor
iv Three motors operated in sequence by DOL starter operated by manual push
button or time delay relay
74 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
a One loop per-cycle
b Continuous operation in a loop
c optional circuit design to represent the same task
v Only one out of three motors to be operated at a time (quiz)
4 Test the functionality of completed project
LESSON 10 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (AC)
75 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 1
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Lamp point 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
76 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
11 Overload Relay 415V 20A 3
12 Three phase induction
motor
5 hp 3
13 Single core PVC insulated
Cable
1mm 2 As required
14 Single core PVC insulated
Cable
25mm 2 As required
15 DIN rail 35 mm As required
16 PVC type Cable tray 50 mm x 50 mm As required
17 Cable ties 4 ldquo As required
18 Flexible wires 05 mm As required
19 PVC Connectors 5 A amp 20 A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the
schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram optional exercise
4 Simple DOL starter
5 Forward reverse DOL starter
6 Test the functionality of completed project
77 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 1
78 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
cm
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Indicating light 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
11 Overload Relay 415V 20A 3
12 Three phase induction motor 5 hp 3
13 Single phase step down
transformer
2500VA 1
14 Single core PVC insulated
Cable
1mm 2 As required
15 Single core PVC insulated
Cable
25mm 2 As required
16 DIN rail 35 mm As required
17 PVC type Cable tray 50 mm x 50 mm As required
18 Cable ties 4 ldquo As required
19 Flexible wires 05 mm As required
20 PVC Connectors 5 A amp 20 A 240 V As required
21 Single pole MCB 6A 240 V 1
22 Single pole MCB 2A 240 V 1
23 Triple pole MCB 20A 415 V 1
24 Mounting board 30 cm x 40 cm x 3
cm
1
25 Relay cw 11 pin socket 10 A 240 Vac 2
26 Time delay relay 10 A 240 Vac 3
27 Triple pole Contactor 20A 240Vac 3
28 Batten type Lamp holder 240Vac 10 A 3
29 Start stop button 240Vac 10A 2
30 Indicating light (Bulb ) 240Vac 25W 3
31 Overload Relay 415V 20A 1
32 Three phase dahlander type
induction motor
5 hp 1
33 Single phase step down
transformer
24024Vac
2500VA
1
79 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
34 Single core PVC insulated
Cable
1mm 2 As required
35 Single core PVC insulated
Cable
25mm 2 As required
36 DIN rail 35 mm As required
37 PVC type Cable tray 50 mm x 50 mm As required
38 Cable ties 4 ldquo As required
39 Flexible wires 075 mm As required
40 PVC Connectors 5 A amp 20 A 240 V As required
41 Terminal block 20A 240Vac As required
Procedures
5 Identify each component according to specification and quantity required from the schematic
diagram attached
6 Test the functionality of each component by using multi-meter or power supply whichever
applicable
7 Wire component according to circuit diagram
8 Three motors operated in sequence by DOL starter operated by manual push button or time
delay relay
a One loop per-cycle
b Continuous operation in a loop
c optional circuit design to represent the same task
d Only one out of three motors to be operated at a time (quiz)
9 Test the functionality of completed project
80 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
BASIC DESIGN INDUSTRIAL MOTOR CONTROL (SEQUENCE CONTROL)
THREE PHASE INDUCTION MOTOR OPERATED IN SEQUENCE BY DIRECT ON LINE
STARTER
LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
81 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
82 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Lcd lamp indicator 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
11 Overload Relay 415V 20A 3
12 Three phase induction motor 5 hp 3
13 Single phase step down transformer 2500VA 1
14 Single core PVC insulated Cable 1mm 2 As required
15 Single core PVC insulated Cable 25mm 2 As required
16 DIN rail 35 mm As required
17 PVC type Cable tray 50 mm x 50 mm As required
18 Cable ties 4 ldquo As required
19 Flexible wires 1 mm Oslash As required
20 PVC Terminal block 10A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the schematic
diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a optional exercise
i Forward Reverse dahlander motor
4 Test the functionality of completed project
83 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
THREE PHASE DAHLANDER TYPE INDUCTION MOTOR OPERATED FORWARD AND
REVERSE OPERATION BY DIRECT ON LINE STARTER
84 ndash 99EASYTECH ENTERPRISE
LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
Introduction
If a motors windings are connected in the star configuration any two phases will be in series across
the supply and hence the line current will be smaller(by 577) than if the windings were connected in
the delta arrangement
Hence larger-type motors with heavy starting currents are first connected in star and then when the
starting currents fall in delta This of course means that all six of the ends of the windings must be
brought to terminations outside the casing (Fig 833)
EZTECH
EZTECH ELECTRICAL INSTALLATION GUIDE
The automatic version of this starter incorporates a timing relay which automatically changes the
connections from star to delta Figs 834 and 835 show the wiring and schematic diagrams for a star
delta starter
Objectives
1 Identify component and the specification
2 Design forward reverse star delta starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
2 ndash 99EASYTECH ENTERPRISE
REV -C
LEGENDMCCB Moulded Case Circuit BreakerTOR Thermal Over Load RelayFOW-C Mains Forward ContactorREV-C Mains Reverse ContactorDC Delta ContactorSC Star ContactorS-SW Mains Selector Switch
SC
V2
W2
U2
DC
V1
W1
U1
TOR
TOR
FOW-C
30A MCCB
TOR
MAIN CIRCUIT FORWARD REVERSE STAR DELTA
RYBN S
-SW
3 PHASEINDUCTION MOTOR
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Relay 10 A 240V 3
5 Triple pole Contactor
6 cw NO NC auxiliary contact
240Vac 20 A 4
7 Overload Relay 415 V 1
8 LED indicator 240vac 5 A 4
9 Start stop button 240Vac 5A 2
10 DIN rail 35 mm As required
11 Flexible wires 1 mm As required
12 Single core PVC insulated
wire
25 mm As required
13 Terminal block 20 A As required
14 Squirrel cage motor 5kW 1
15 5 pin plug and socket 415V 20A 1
16 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
3 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
a Manual star delta
b Manual Forward reverse star delta starter
c Automatic star delta starter
d Automatic Forward reverse star delta starter
4 Test the functionality of completed project
4 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
Objectives
1 Identify component and the specification
2 Design auto transformer starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
5 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Autotransformer starter is used to start a 3 phase induction motor that has a rating between 10 to 15 hp
6 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Autotransformer set 10Kw 415 V 50 Hz 1
5 Triple pole Contactor 240Vac 4
6 Batten type Lamp holder 240 Vac 105 A 4
7 Start stop button 240Vac 10A 4
8 Filament lamp (Bulb ) 240Vac 40W 4
9 DIN rail 35 mm As required
10 Flexible wires 1 mm As required
7 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
11 Single core PVC insulated
wire
25 mm As required
12 Terminal block 20 A As required
13 Squirrel cage motor 10kW 1
14 5 pin plug and socket 415V 20A 1
15 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a open transient autotransformer starter
b close transient autotransformer starter
c Forward reverse autotransformer starter
4 Test the functionality of completed project
8 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
Objectives
1 Identify component and the specification
2 Design rotor resistance starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
9 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Rotor Resistor set 10kW 1
5 Triple pole Contactor 240Vac 20A 4
6 Indicating light 240vac 5 A 4
7 Start stop push button 240Vac 5A 4
8 DIN rail 35 mm As required
9 Flexible wires 1 mm 2 As required
10 Single core PVC insulated wire 25 mm 2 As required
11 Terminal block 20 A As required
12 Slip Ring motor 10kW 1
13 5 pin round 3 phase socket 415V 20A 1
14 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
10 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
4 Test the functionality of completed project
a Dead circuit test b Life circuit test
5 Measure starting and running Amps
LESSON 16
TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
An installation in general will suffer damage
Damage usually occurs on the electric motor control as follows
1 Damage to the main circuit
2 Damage to the control circuit
The cause of the damage
i Overcurrent overload short circuit
ii Leakage current to ground
iii Equipment malfunction
iv The main control circuit
a Trip of main circuit protection devices fire
b Defect of motor terminal such as short circuit fire loose
v The control circuit is not functioning -
a contactor relay relay time overload relay does not work damaged burned
b Loose cable connection disconnected
Detecting and Repairing Damage
Examples of damage are as follows
i Motor does not work
ii Motor function and overload relay trips
iii Motor function but only partially functional control circuit
Methods of detecting damage
Among the known methods necessary to detect damage are as follows
1 Turn off the electricity at the main switch (main switch) in order to avoid any danger during the
work carried out to detect damage
2 Check all the protective gear that controls the motor control main circuit
11 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
3 Make sure the damage function control circuit
4 Check the control circuit according to the schematic circuit diagram of the motor control
5 Check the operation of the control circuit
Note
Use wiring that has been installed on the SYSTEM OF MOTOR CONTROL BOARD by Forward
Reverse control circuit for Star Delta to test and look for damage
SELF-ASSESSMENT QUESTIONS
1 (a) Explain what is meant by the term lsquoback emfrsquo in a motor
(b) Outline the basic differences between series shunt and compound wound dc motors
2 (a) With the aid of diagrams explain how the speed of series shunt and compound-wound motors
may be controlled
(b) A 440V dc shunt-wound motor has a field resistance of 200R and an armature resistance of 06 R
When its speed is 20 rev d second the current drawn from the supply is 122A Calculate its back
emf at this speed If the speed were decreased to 19 revssecond the field flux remaining unchanged
calculate the new back emf and the new armature current
3 A load of 64 kW at 240 V is supplied from the terminals of a shunt-wound dc generator The field
resistance is 180 A Calculate the armature current
4 (a) Explain with the aid of a diagram how a rotating magnetic field may be
(b) What is meant by lsquosynchronous speedrsquo
Calculate the synchronous obtained speed of a 12 pole motor if the supply frequency is 50Hz
5 (a) Explain the action of a synchronous motor
(b) What methods are available to start a synchronous motor Explain with diagrams
6 (a) Explain the action of a cage induction motor
(b) What is meant by the term lsquosliprsquo
Calculate the percentage slip of a six pole induction motor running at 162 revssecond from a 50 Hz
supply
7 Describe with sketches three different ways of starting a single-phase induction motor
12 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
8 Explain with the aid of a sketch the action of a three-phase DOL starter
What are dashpots used for How are remote start and stop buttons connected
9 A I0 kW 240V 50Hz single-phase cage rotor induction motor is 85efficient and has a PF of 068
lagging Calculate the motor current and the value of capacitor required to raise the PF to 093
lagging
10 Calculate the torque developed by an 18 kW four-pole induction motor run at 35 slip from a
50Hz supply
APPENDIX 1
13 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 11
14 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 111
Attachment Reference
httpswwwtlc-directcoukBook621htm
httpwwwstgovmyindexphpms
15 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
1 Identify component and the specification
2 Wire component according to the schematic diagram
3 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting bay Board Perforated metal 180 cm x 180 cm 1
2 k Watt hour meter 415V 60A 1
3 MCCB 415V 60A
4 ELCB RCCB In=60A415 Vac I trip=30mA 1
5 5 pin round Socket and
plug
415Vac 32A 4
6 Single pole MCB 6A 1
7 Triple pole MCB 20A 2
8 Triple pole Main switch 60A 1
9 DOL starter 240Vac 2
10 3 phase induction motor 2hp 415 Vac 1
11 1 phase induction motor 1
12 Metal trunking 30 mm x30 mm As required
13 Self tapping Wood screw 4 mm x 20 mm As required
14 DIN rail 25 mm x 1mm
15 GI steel rigid conduit 20mm As required
16 Flexible conduit 20mm As required
17 End box 20 mm 4
18 Flexible wires 05 mm As required
19 Connectors 10 A As required
Procedures
1 Identify each components and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
4 Test the functionality of completed project
1 dead circuit 2 life circuit test
5 Record the current drawn by the load as connected in star and delta
Note Proper earthing should be made
53 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 8 INSPECTION AND TESTING OF ELECTRICAL INSTALLATION
On completion of a wiring installation a number of tests on the installation have to be conducted to
ascertain that the wiring circuits and connected appliances are safe for use Prior to carrying out the
tests an inspection has to be done The results of the inspectionsupervision and test have to be
presented in Form G (as in Appendix IV) and Form H (as in Appendix V)
To have the test certification as in Form H the following tests shall be conducted
i Continuity Test
ii Insulation Resistance Test
iii Polarity Test
iv Earth Electrode Resistance test and
v Residual Current Device Test
1 Continuity Test
There are 3 main types of continuity tests for the final circuits-
i Protection Conductor Continuity Test
ii Final Ring Circuit Conductor Continuity Test
iii Live and Neutral Conductor Continuity Test
a) Protection Conductor Continuity Test
bull To ascertain that all protection conductors are connected in the correct and effective manner
bull Test equipment ndash Multimeter (Ohm range) or Ohm meter
54 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
bull Test Method
1 1048766 Ensure that the main switch RCD and MCB are open circuited (switched off) and all loads
are disconnected
2 1048766 Connected the test leads as in the Figure 81 The meter reading shall be less than 1 Ω
55 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Final Ring Circuit Conductor Continuity Test
bull To ensure that all conductors around the ring circuit have continuity
bull Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
bull Test Method
1 1048766 Disconnect both the supply source live conductors from the MCB the neutral conductor
from the neutral terminals and the earth conductor from the earth terminal in the distribution
fuse box
2 1048766 Connect the test leads as in the Figure 82 (EE)
3 1048766 Repeat the procedure for (L-L) and (N-N)
4 1048766 The meter reading value shall be less than 1 ohm
56 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Live and Neutral Conductor Continuity Test
a To ensure that each conductor in the circuit has continuity
b Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
2 Test Method
1 1048766 Switch off the Main switch RCD and MCB
2 1048766 Disconnect all loads
3 1048766 Switch on all switches in the circuit
4 1048766 Disconnect the fusesfinal circuit breakers and close the circuit
5 1048766 Carry out the test as shown in Figure 83
6 1048766 The meter reading value shall be less than 1Ω
57 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
58 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
CONTINUITY TEST
Insulation Resistance Test
i Ensure that there is no leakage current between phase conductors phase and neutral conductors and
phase conductor and earth
ii Test the strength of the cable insulation
iii Test Equipment ndash Insulation Resistance Tester operating voltage is 250VDC or 500VDC
iv Test Method
1 1048766 Switch off main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
59 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
4 1048766 Carry out test as in the Table below
5 1048766 Meter reading value shall be less than 1 Megaohm
60 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
61 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Insulation resitance test
62 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
INSULATION RESISTANCE TEST BETWEEN CONDUCTORS AND OPPOSITE POLARITY
Polarity Testi Ensure that each fuse or single pole control and protection device is connected only in the phase
conductor
ii Intermediate contact of Edison screw lamp holder is connected to the phase conductor
iii Ensure that phase neutral and earth conductors at socket outlets are connected at the correct
terminals
iv Test Equipment ndash Multimeter (Ohm range) or Ohm meter
v Test Method
1 1048766 Switch off Main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in Figure 85
63 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
5 1048766 Test switches and single phase control devices at the phase conductors
6 1048766 Test socket outlet connection sources
7 1048766 Test Edison screw lamp holder connections
8 1048766 Meter reading value shall be less than 1 Ω
64 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Polarity test
65 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Earth Electrode Resistance Testi To test the earth electrode resistance
ii To ascertain the suitability of the location of the electrode
iii To ensure that the electrode is not buried within the resistance area of another electrode
iv Test equipment ndash Earth Resistance Tester
v Test method -
1 1048766 Terminal rsquoErsquo is connected to the electrode to be tested (green conductor)
2 1048766 Terminal lsquoPrsquo is connected to the potential spike (yellow conductor) at a distance of 10
meters from the earth electrode
3 1048766 Terminal lsquoCrsquo is connected to the current spike (red conductor) at a distance of 20 meters
from the earth electrode
Earth Electrode Resistance Measurement Method (Figure 86)
This test must be repeated at least three times to ensure that the reading is not affected by interacting
earthing regions
i Record the first reading (Z1) Example Z1 = 10 Ω
ii Move the voltage spike to a distance of 6 meters from the original position Record the second
reading (Z2 ) Example Z2 = 10 Ω
iii Move the voltage spike to a distance of 6 meters from the original position Record the third
reading (Z3) Example Z3 = 10 Ω
66 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Residual Current Device Testi Ensure that the residual current device (RCD) trips within the set time on the occurrence of current
leakage to earth
ii Test Equipment ndash RCD Tester RCCB Tester
iii Test Method 1
1 1048766 Use the Trip Test Button
2 1048766 Press the trip button found on the RCD to determine if it trips or otherwise This test would
not be able to determine the sensitivity of the RCD nor the time taken for it to trip
iv Test Method 2
i 1048766 Use a RCD Tester
ii This equipment is equipped with a 13A plug which can be connected to a 13A socket outlet
Select the RCD sensitivity to be the same as the sensitivity of the RCD to be tested to
determine if the RCD can trip The time to trip shall not exceed 40 mS
iii 1048766 Test method ndash
a) Position the selection switch in accordance with the sensitivity of the RCD used
Example 100 mA 01 A
b) Position the operations switch to lsquoNo Triprsquo (frac12 Rated mA = 50) connect the 3 pin plug to
the 13A socket outlet
67 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
c) Switch on the 13A socket outlet ndash ensure that the P-N and P-E lights light up
This shows that the polarity is correct (Note if both the lights as above do not light up the test cannot
be continued)
d) Press the test button ndash the reading shows less than 200 mS and simultaneously the lsquotestrsquo light lights
up and the P-N and P-E lights do not light up At that instant the RCD will not trip
e) Move the selection switch to 180o (+ve wave) ndash repeat steps (d) and (e) Move the operations
switch to lsquoTriprsquo (Rated mA = 100)
g) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200mS
h) Move the selection switch to 0o (-ve wave)
i) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
j) The above test is repeated until a near correct reading is obtained
k) Record the test results
l) Change the operations switch to lsquoFast Triprsquo and press the test button ndash RCD will trip within a
time not exceeding 40 millisecond
m) Repeat a number of times at 0o or 180o
On completion of a wiring installation a number of tests on the installation have to be conducted to
ascertain that the wiring circuits and connected appliances are safe for use Prior to carrying out the
tests an inspection has to be done the following tests shall be conducted
i Continuity Test
ii Insulation Resistance Test
iii Polarity Test
iv Earth Electrode Resistance test and
v Residual Current Device Test
821 Continuity Test
There are 3 main types of continuity tests for the final circuits-
i Protection Conductor Continuity Test
ii Final Ring Circuit Conductor Continuity Test
68 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
iii Live and Neutral Conductor Continuity Test
a) Protection Conductor Continuity Test
bull To ascertain that all protection conductors are connected in the correct and effective manner
bull Test equipment ndash Multimeter (Ohm range) or Ohm meter
bull Test Method
1 1048766 Ensure that the main switch RCD and MCB are open circuited (switched off) and all loads are
disconnected
2 1048766 Connected the test leads as in the Figure 81
3 1048766 The meter reading shall be less than 1 Ω
Final Ring Circuit Conductor Continuity Test
bull To ensure that all conductors around the ring circuit have continuity
bull Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
bull Test Method
1 1048766 Disconnect both the supply source live conductors from the MCB the neutral conductor
from the neutral terminals and the earth conductor from the earth terminal in the distribution
fuse box
2 1048766 Connect the test leads as in the Figure 82 (EE)
3 1048766 Repeat the procedure for (L-L) and (N-N)
4 1048766 The meter reading value shall be less than 1 ohm Figure 82 - Final Ring Circuit Conductor
Continuity Test Ohm Meter
Disconnect both the supply source cables from mcbfuse
Take readings at earth conductors of both sources and note resistance readings
Live and Neutral Conductor Continuity Test
1 To ensure that each conductor in the circuit has continuity
2 Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
3 Test Method
1 1048766 Switch off the Main switch RCD and MCB
2 1048766 Disconnect all loads
3 1048766 Switch on all switches in the circuit
4 1048766 Disconnect the fusesfinal circuit breakers and close the circuit
5 1048766 Carry out the test as shown in Figure 83
6 1048766 The meter reading value shall be less than 1 ohm Figure 83 - Live and Neutral
Conductor Continuity Test Ohm Meter
Insulation Resistance Test
69 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
i Ensure that there is no leakage current between phase conductors phase and neutral conductors and
phase conductor and earth
ii Test the strength of the cable insulation
iii Test Equipment ndash Insulation Resistance Tester Operating voltage is 250VDC or 500VDC
iv Test Method
1 1048766 Switch off main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in the Table below
5 1048766 Meter reading value shall be less than 1 Megaohm
Polarity Test
i Ensure that each fuse or single pole control and protection device is connected only in the phase
conductor
ii Intermediate contact of Edison screw lamp holder is connected to the phase conductor
iii Ensure that phase neutral and earth conductors at socket outlets are connected at the correct
terminals
iv Test Equipment ndash Multimeter (Ohm range) or Ohm meter
v Test Method
1 1048766 Switch off Main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in Figure 85
5 1048766 Test switches and single phase control devices at the phase conductors
6 1048766 Test socket outlet connection sources
7 1048766 Test Edison screw lamp holder connections
8 1048766 Meter reading value shall be less than 1 Ω
Earth Electrode Resistance Test
i To test the earth electrode resistance
70 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
ii To ascertain the suitability of the location of the electrode
iii To ensure that the electrode is not buried within the resistance area of another electrode
iv Test equipment ndash Earth Resistance Tester
v Test method -
1 1048766 Terminal rsquoErsquo is connected to the electrode to be tested (green conductor)
2 1048766 Terminal lsquoPrsquo is connected to the potential spike (yellow conductor) at a distance of 10
meters from the earth electrode
3 1048766 Terminal lsquoCrsquo is connected to the current spike (red conductor) at a distance of 20 meters
from the earth electrode E P C Electrode 10 meter 10 meter
Figure 86 ndash Earth Electrode Resistance Measurement Test Equipment
Earth Electrode Resistance Measurement Method (Figure 86)
This test must be repeated at least three times to ensure that the reading is not affected by interacting
earthing regions
i Record the first reading (Z1) Example Z1 = 10 Ω
ii Move the voltage spike to a distance of 6 meters from the original position Record the second
reading (Z2) Example Z2 = 10 Ω
iii Move the voltage spike to a distance of 6 meters from the original position Record the third
reading (Z3)
Example Z3 = 10 Ω
Residual Current Device Test
71 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
i Ensure that the residual current device (RCD) trips within the set time on the occurrence of current
leakage to earth
ii Test Equipment ndash RCD Tester RCCB Tester
iii Test Method 1
1 1048766 Use the Trip Test Button
2 1048766 Press the trip button found on the RCD to determine if it trips or otherwise This test would
not be able to determine the sensitivity of the RCD nor the time taken for it to trip
iv Test Method 2
1048766 Use a RCD Tester
This equipment is equipped with a 13A plug which can be connected to a 13A socket outlet Select the
RCD sensitivity to be the same as the sensitivity of the RCD to be tested to determine if the RCD can
trip The time to trip shall not exceed 40 mS
1048766 Test method ndash
a) Position the selection switch in accordance with the sensitivity of the RCD used
Example 100 mA 01 A
b) Position the operations switch to lsquoNo Triprsquo (frac12 Rated mA = 50) connect the 3 pin plug to
the 13A socket outlet
c) Switch on the 13A socket outlet ndash ensure that the P-N and P-E lights light up This shows that
the polarity is correct (Note if both the lights as above do not light up the test cannot be
continued)
d) Press the test button ndash the reading shows less than 200 millisecond and simultaneously the
lsquotestrsquo light lights up and the P-N and P-E lights do not light up At that instant the RCD will
not trip
e) Move the selection switch to 180o (+ve wave) ndash repeat steps (d) and (e) = 100)
f) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
g) Move the selection switch to 0o (-ve wave)
h) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
i) The above test is repeated until a near correct reading is obtained
j) Record the test results
k) Change the operations switch to lsquoFast Triprsquo and press the test button ndash RCD will trip within a
time not exceeding 40 mS
l) Repeat a number of times at 0o or 180o
72 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 9 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (DC)
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
73 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Start stop button 240Vac 5A 2
9 Filament lamp (Bulb ) 240Vac 40W 3
10 Overload Relay 415V 20A 3
11 Three phase induction motor 5 hp 3
12 Single phase step down transformer 2500VA 1
13 Single core PVC insulated Cable 1mm 2 As required
14 Single core PVC insulated Cable 25mm 2 As required
15 DIN rail 35 mm As required
16 PVC type Cable tray 50 mm x 50 mm As required
17 Cable ties 4 ldquo As required
18 Flexible wires 05 mm As required
19 PVC Connectors 5 A amp 20 A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the schematic
diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a optional exercise
i Simple DOL starter
ii Forward reverse DOL starter
iii Forward Reverse Dahlander motor
iv Three motors operated in sequence by DOL starter operated by manual push
button or time delay relay
74 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
a One loop per-cycle
b Continuous operation in a loop
c optional circuit design to represent the same task
v Only one out of three motors to be operated at a time (quiz)
4 Test the functionality of completed project
LESSON 10 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (AC)
75 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 1
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Lamp point 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
76 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
11 Overload Relay 415V 20A 3
12 Three phase induction
motor
5 hp 3
13 Single core PVC insulated
Cable
1mm 2 As required
14 Single core PVC insulated
Cable
25mm 2 As required
15 DIN rail 35 mm As required
16 PVC type Cable tray 50 mm x 50 mm As required
17 Cable ties 4 ldquo As required
18 Flexible wires 05 mm As required
19 PVC Connectors 5 A amp 20 A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the
schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram optional exercise
4 Simple DOL starter
5 Forward reverse DOL starter
6 Test the functionality of completed project
77 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 1
78 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
cm
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Indicating light 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
11 Overload Relay 415V 20A 3
12 Three phase induction motor 5 hp 3
13 Single phase step down
transformer
2500VA 1
14 Single core PVC insulated
Cable
1mm 2 As required
15 Single core PVC insulated
Cable
25mm 2 As required
16 DIN rail 35 mm As required
17 PVC type Cable tray 50 mm x 50 mm As required
18 Cable ties 4 ldquo As required
19 Flexible wires 05 mm As required
20 PVC Connectors 5 A amp 20 A 240 V As required
21 Single pole MCB 6A 240 V 1
22 Single pole MCB 2A 240 V 1
23 Triple pole MCB 20A 415 V 1
24 Mounting board 30 cm x 40 cm x 3
cm
1
25 Relay cw 11 pin socket 10 A 240 Vac 2
26 Time delay relay 10 A 240 Vac 3
27 Triple pole Contactor 20A 240Vac 3
28 Batten type Lamp holder 240Vac 10 A 3
29 Start stop button 240Vac 10A 2
30 Indicating light (Bulb ) 240Vac 25W 3
31 Overload Relay 415V 20A 1
32 Three phase dahlander type
induction motor
5 hp 1
33 Single phase step down
transformer
24024Vac
2500VA
1
79 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
34 Single core PVC insulated
Cable
1mm 2 As required
35 Single core PVC insulated
Cable
25mm 2 As required
36 DIN rail 35 mm As required
37 PVC type Cable tray 50 mm x 50 mm As required
38 Cable ties 4 ldquo As required
39 Flexible wires 075 mm As required
40 PVC Connectors 5 A amp 20 A 240 V As required
41 Terminal block 20A 240Vac As required
Procedures
5 Identify each component according to specification and quantity required from the schematic
diagram attached
6 Test the functionality of each component by using multi-meter or power supply whichever
applicable
7 Wire component according to circuit diagram
8 Three motors operated in sequence by DOL starter operated by manual push button or time
delay relay
a One loop per-cycle
b Continuous operation in a loop
c optional circuit design to represent the same task
d Only one out of three motors to be operated at a time (quiz)
9 Test the functionality of completed project
80 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
BASIC DESIGN INDUSTRIAL MOTOR CONTROL (SEQUENCE CONTROL)
THREE PHASE INDUCTION MOTOR OPERATED IN SEQUENCE BY DIRECT ON LINE
STARTER
LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
81 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
82 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Lcd lamp indicator 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
11 Overload Relay 415V 20A 3
12 Three phase induction motor 5 hp 3
13 Single phase step down transformer 2500VA 1
14 Single core PVC insulated Cable 1mm 2 As required
15 Single core PVC insulated Cable 25mm 2 As required
16 DIN rail 35 mm As required
17 PVC type Cable tray 50 mm x 50 mm As required
18 Cable ties 4 ldquo As required
19 Flexible wires 1 mm Oslash As required
20 PVC Terminal block 10A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the schematic
diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a optional exercise
i Forward Reverse dahlander motor
4 Test the functionality of completed project
83 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
THREE PHASE DAHLANDER TYPE INDUCTION MOTOR OPERATED FORWARD AND
REVERSE OPERATION BY DIRECT ON LINE STARTER
84 ndash 99EASYTECH ENTERPRISE
LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
Introduction
If a motors windings are connected in the star configuration any two phases will be in series across
the supply and hence the line current will be smaller(by 577) than if the windings were connected in
the delta arrangement
Hence larger-type motors with heavy starting currents are first connected in star and then when the
starting currents fall in delta This of course means that all six of the ends of the windings must be
brought to terminations outside the casing (Fig 833)
EZTECH
EZTECH ELECTRICAL INSTALLATION GUIDE
The automatic version of this starter incorporates a timing relay which automatically changes the
connections from star to delta Figs 834 and 835 show the wiring and schematic diagrams for a star
delta starter
Objectives
1 Identify component and the specification
2 Design forward reverse star delta starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
2 ndash 99EASYTECH ENTERPRISE
REV -C
LEGENDMCCB Moulded Case Circuit BreakerTOR Thermal Over Load RelayFOW-C Mains Forward ContactorREV-C Mains Reverse ContactorDC Delta ContactorSC Star ContactorS-SW Mains Selector Switch
SC
V2
W2
U2
DC
V1
W1
U1
TOR
TOR
FOW-C
30A MCCB
TOR
MAIN CIRCUIT FORWARD REVERSE STAR DELTA
RYBN S
-SW
3 PHASEINDUCTION MOTOR
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Relay 10 A 240V 3
5 Triple pole Contactor
6 cw NO NC auxiliary contact
240Vac 20 A 4
7 Overload Relay 415 V 1
8 LED indicator 240vac 5 A 4
9 Start stop button 240Vac 5A 2
10 DIN rail 35 mm As required
11 Flexible wires 1 mm As required
12 Single core PVC insulated
wire
25 mm As required
13 Terminal block 20 A As required
14 Squirrel cage motor 5kW 1
15 5 pin plug and socket 415V 20A 1
16 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
3 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
a Manual star delta
b Manual Forward reverse star delta starter
c Automatic star delta starter
d Automatic Forward reverse star delta starter
4 Test the functionality of completed project
4 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
Objectives
1 Identify component and the specification
2 Design auto transformer starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
5 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Autotransformer starter is used to start a 3 phase induction motor that has a rating between 10 to 15 hp
6 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Autotransformer set 10Kw 415 V 50 Hz 1
5 Triple pole Contactor 240Vac 4
6 Batten type Lamp holder 240 Vac 105 A 4
7 Start stop button 240Vac 10A 4
8 Filament lamp (Bulb ) 240Vac 40W 4
9 DIN rail 35 mm As required
10 Flexible wires 1 mm As required
7 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
11 Single core PVC insulated
wire
25 mm As required
12 Terminal block 20 A As required
13 Squirrel cage motor 10kW 1
14 5 pin plug and socket 415V 20A 1
15 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a open transient autotransformer starter
b close transient autotransformer starter
c Forward reverse autotransformer starter
4 Test the functionality of completed project
8 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
Objectives
1 Identify component and the specification
2 Design rotor resistance starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
9 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Rotor Resistor set 10kW 1
5 Triple pole Contactor 240Vac 20A 4
6 Indicating light 240vac 5 A 4
7 Start stop push button 240Vac 5A 4
8 DIN rail 35 mm As required
9 Flexible wires 1 mm 2 As required
10 Single core PVC insulated wire 25 mm 2 As required
11 Terminal block 20 A As required
12 Slip Ring motor 10kW 1
13 5 pin round 3 phase socket 415V 20A 1
14 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
10 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
4 Test the functionality of completed project
a Dead circuit test b Life circuit test
5 Measure starting and running Amps
LESSON 16
TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
An installation in general will suffer damage
Damage usually occurs on the electric motor control as follows
1 Damage to the main circuit
2 Damage to the control circuit
The cause of the damage
i Overcurrent overload short circuit
ii Leakage current to ground
iii Equipment malfunction
iv The main control circuit
a Trip of main circuit protection devices fire
b Defect of motor terminal such as short circuit fire loose
v The control circuit is not functioning -
a contactor relay relay time overload relay does not work damaged burned
b Loose cable connection disconnected
Detecting and Repairing Damage
Examples of damage are as follows
i Motor does not work
ii Motor function and overload relay trips
iii Motor function but only partially functional control circuit
Methods of detecting damage
Among the known methods necessary to detect damage are as follows
1 Turn off the electricity at the main switch (main switch) in order to avoid any danger during the
work carried out to detect damage
2 Check all the protective gear that controls the motor control main circuit
11 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
3 Make sure the damage function control circuit
4 Check the control circuit according to the schematic circuit diagram of the motor control
5 Check the operation of the control circuit
Note
Use wiring that has been installed on the SYSTEM OF MOTOR CONTROL BOARD by Forward
Reverse control circuit for Star Delta to test and look for damage
SELF-ASSESSMENT QUESTIONS
1 (a) Explain what is meant by the term lsquoback emfrsquo in a motor
(b) Outline the basic differences between series shunt and compound wound dc motors
2 (a) With the aid of diagrams explain how the speed of series shunt and compound-wound motors
may be controlled
(b) A 440V dc shunt-wound motor has a field resistance of 200R and an armature resistance of 06 R
When its speed is 20 rev d second the current drawn from the supply is 122A Calculate its back
emf at this speed If the speed were decreased to 19 revssecond the field flux remaining unchanged
calculate the new back emf and the new armature current
3 A load of 64 kW at 240 V is supplied from the terminals of a shunt-wound dc generator The field
resistance is 180 A Calculate the armature current
4 (a) Explain with the aid of a diagram how a rotating magnetic field may be
(b) What is meant by lsquosynchronous speedrsquo
Calculate the synchronous obtained speed of a 12 pole motor if the supply frequency is 50Hz
5 (a) Explain the action of a synchronous motor
(b) What methods are available to start a synchronous motor Explain with diagrams
6 (a) Explain the action of a cage induction motor
(b) What is meant by the term lsquosliprsquo
Calculate the percentage slip of a six pole induction motor running at 162 revssecond from a 50 Hz
supply
7 Describe with sketches three different ways of starting a single-phase induction motor
12 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
8 Explain with the aid of a sketch the action of a three-phase DOL starter
What are dashpots used for How are remote start and stop buttons connected
9 A I0 kW 240V 50Hz single-phase cage rotor induction motor is 85efficient and has a PF of 068
lagging Calculate the motor current and the value of capacitor required to raise the PF to 093
lagging
10 Calculate the torque developed by an 18 kW four-pole induction motor run at 35 slip from a
50Hz supply
APPENDIX 1
13 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 11
14 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 111
Attachment Reference
httpswwwtlc-directcoukBook621htm
httpwwwstgovmyindexphpms
15 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 8 INSPECTION AND TESTING OF ELECTRICAL INSTALLATION
On completion of a wiring installation a number of tests on the installation have to be conducted to
ascertain that the wiring circuits and connected appliances are safe for use Prior to carrying out the
tests an inspection has to be done The results of the inspectionsupervision and test have to be
presented in Form G (as in Appendix IV) and Form H (as in Appendix V)
To have the test certification as in Form H the following tests shall be conducted
i Continuity Test
ii Insulation Resistance Test
iii Polarity Test
iv Earth Electrode Resistance test and
v Residual Current Device Test
1 Continuity Test
There are 3 main types of continuity tests for the final circuits-
i Protection Conductor Continuity Test
ii Final Ring Circuit Conductor Continuity Test
iii Live and Neutral Conductor Continuity Test
a) Protection Conductor Continuity Test
bull To ascertain that all protection conductors are connected in the correct and effective manner
bull Test equipment ndash Multimeter (Ohm range) or Ohm meter
54 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
bull Test Method
1 1048766 Ensure that the main switch RCD and MCB are open circuited (switched off) and all loads
are disconnected
2 1048766 Connected the test leads as in the Figure 81 The meter reading shall be less than 1 Ω
55 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Final Ring Circuit Conductor Continuity Test
bull To ensure that all conductors around the ring circuit have continuity
bull Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
bull Test Method
1 1048766 Disconnect both the supply source live conductors from the MCB the neutral conductor
from the neutral terminals and the earth conductor from the earth terminal in the distribution
fuse box
2 1048766 Connect the test leads as in the Figure 82 (EE)
3 1048766 Repeat the procedure for (L-L) and (N-N)
4 1048766 The meter reading value shall be less than 1 ohm
56 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Live and Neutral Conductor Continuity Test
a To ensure that each conductor in the circuit has continuity
b Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
2 Test Method
1 1048766 Switch off the Main switch RCD and MCB
2 1048766 Disconnect all loads
3 1048766 Switch on all switches in the circuit
4 1048766 Disconnect the fusesfinal circuit breakers and close the circuit
5 1048766 Carry out the test as shown in Figure 83
6 1048766 The meter reading value shall be less than 1Ω
57 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
58 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
CONTINUITY TEST
Insulation Resistance Test
i Ensure that there is no leakage current between phase conductors phase and neutral conductors and
phase conductor and earth
ii Test the strength of the cable insulation
iii Test Equipment ndash Insulation Resistance Tester operating voltage is 250VDC or 500VDC
iv Test Method
1 1048766 Switch off main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
59 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
4 1048766 Carry out test as in the Table below
5 1048766 Meter reading value shall be less than 1 Megaohm
60 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
61 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Insulation resitance test
62 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
INSULATION RESISTANCE TEST BETWEEN CONDUCTORS AND OPPOSITE POLARITY
Polarity Testi Ensure that each fuse or single pole control and protection device is connected only in the phase
conductor
ii Intermediate contact of Edison screw lamp holder is connected to the phase conductor
iii Ensure that phase neutral and earth conductors at socket outlets are connected at the correct
terminals
iv Test Equipment ndash Multimeter (Ohm range) or Ohm meter
v Test Method
1 1048766 Switch off Main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in Figure 85
63 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
5 1048766 Test switches and single phase control devices at the phase conductors
6 1048766 Test socket outlet connection sources
7 1048766 Test Edison screw lamp holder connections
8 1048766 Meter reading value shall be less than 1 Ω
64 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Polarity test
65 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Earth Electrode Resistance Testi To test the earth electrode resistance
ii To ascertain the suitability of the location of the electrode
iii To ensure that the electrode is not buried within the resistance area of another electrode
iv Test equipment ndash Earth Resistance Tester
v Test method -
1 1048766 Terminal rsquoErsquo is connected to the electrode to be tested (green conductor)
2 1048766 Terminal lsquoPrsquo is connected to the potential spike (yellow conductor) at a distance of 10
meters from the earth electrode
3 1048766 Terminal lsquoCrsquo is connected to the current spike (red conductor) at a distance of 20 meters
from the earth electrode
Earth Electrode Resistance Measurement Method (Figure 86)
This test must be repeated at least three times to ensure that the reading is not affected by interacting
earthing regions
i Record the first reading (Z1) Example Z1 = 10 Ω
ii Move the voltage spike to a distance of 6 meters from the original position Record the second
reading (Z2 ) Example Z2 = 10 Ω
iii Move the voltage spike to a distance of 6 meters from the original position Record the third
reading (Z3) Example Z3 = 10 Ω
66 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Residual Current Device Testi Ensure that the residual current device (RCD) trips within the set time on the occurrence of current
leakage to earth
ii Test Equipment ndash RCD Tester RCCB Tester
iii Test Method 1
1 1048766 Use the Trip Test Button
2 1048766 Press the trip button found on the RCD to determine if it trips or otherwise This test would
not be able to determine the sensitivity of the RCD nor the time taken for it to trip
iv Test Method 2
i 1048766 Use a RCD Tester
ii This equipment is equipped with a 13A plug which can be connected to a 13A socket outlet
Select the RCD sensitivity to be the same as the sensitivity of the RCD to be tested to
determine if the RCD can trip The time to trip shall not exceed 40 mS
iii 1048766 Test method ndash
a) Position the selection switch in accordance with the sensitivity of the RCD used
Example 100 mA 01 A
b) Position the operations switch to lsquoNo Triprsquo (frac12 Rated mA = 50) connect the 3 pin plug to
the 13A socket outlet
67 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
c) Switch on the 13A socket outlet ndash ensure that the P-N and P-E lights light up
This shows that the polarity is correct (Note if both the lights as above do not light up the test cannot
be continued)
d) Press the test button ndash the reading shows less than 200 mS and simultaneously the lsquotestrsquo light lights
up and the P-N and P-E lights do not light up At that instant the RCD will not trip
e) Move the selection switch to 180o (+ve wave) ndash repeat steps (d) and (e) Move the operations
switch to lsquoTriprsquo (Rated mA = 100)
g) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200mS
h) Move the selection switch to 0o (-ve wave)
i) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
j) The above test is repeated until a near correct reading is obtained
k) Record the test results
l) Change the operations switch to lsquoFast Triprsquo and press the test button ndash RCD will trip within a
time not exceeding 40 millisecond
m) Repeat a number of times at 0o or 180o
On completion of a wiring installation a number of tests on the installation have to be conducted to
ascertain that the wiring circuits and connected appliances are safe for use Prior to carrying out the
tests an inspection has to be done the following tests shall be conducted
i Continuity Test
ii Insulation Resistance Test
iii Polarity Test
iv Earth Electrode Resistance test and
v Residual Current Device Test
821 Continuity Test
There are 3 main types of continuity tests for the final circuits-
i Protection Conductor Continuity Test
ii Final Ring Circuit Conductor Continuity Test
68 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
iii Live and Neutral Conductor Continuity Test
a) Protection Conductor Continuity Test
bull To ascertain that all protection conductors are connected in the correct and effective manner
bull Test equipment ndash Multimeter (Ohm range) or Ohm meter
bull Test Method
1 1048766 Ensure that the main switch RCD and MCB are open circuited (switched off) and all loads are
disconnected
2 1048766 Connected the test leads as in the Figure 81
3 1048766 The meter reading shall be less than 1 Ω
Final Ring Circuit Conductor Continuity Test
bull To ensure that all conductors around the ring circuit have continuity
bull Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
bull Test Method
1 1048766 Disconnect both the supply source live conductors from the MCB the neutral conductor
from the neutral terminals and the earth conductor from the earth terminal in the distribution
fuse box
2 1048766 Connect the test leads as in the Figure 82 (EE)
3 1048766 Repeat the procedure for (L-L) and (N-N)
4 1048766 The meter reading value shall be less than 1 ohm Figure 82 - Final Ring Circuit Conductor
Continuity Test Ohm Meter
Disconnect both the supply source cables from mcbfuse
Take readings at earth conductors of both sources and note resistance readings
Live and Neutral Conductor Continuity Test
1 To ensure that each conductor in the circuit has continuity
2 Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
3 Test Method
1 1048766 Switch off the Main switch RCD and MCB
2 1048766 Disconnect all loads
3 1048766 Switch on all switches in the circuit
4 1048766 Disconnect the fusesfinal circuit breakers and close the circuit
5 1048766 Carry out the test as shown in Figure 83
6 1048766 The meter reading value shall be less than 1 ohm Figure 83 - Live and Neutral
Conductor Continuity Test Ohm Meter
Insulation Resistance Test
69 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
i Ensure that there is no leakage current between phase conductors phase and neutral conductors and
phase conductor and earth
ii Test the strength of the cable insulation
iii Test Equipment ndash Insulation Resistance Tester Operating voltage is 250VDC or 500VDC
iv Test Method
1 1048766 Switch off main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in the Table below
5 1048766 Meter reading value shall be less than 1 Megaohm
Polarity Test
i Ensure that each fuse or single pole control and protection device is connected only in the phase
conductor
ii Intermediate contact of Edison screw lamp holder is connected to the phase conductor
iii Ensure that phase neutral and earth conductors at socket outlets are connected at the correct
terminals
iv Test Equipment ndash Multimeter (Ohm range) or Ohm meter
v Test Method
1 1048766 Switch off Main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in Figure 85
5 1048766 Test switches and single phase control devices at the phase conductors
6 1048766 Test socket outlet connection sources
7 1048766 Test Edison screw lamp holder connections
8 1048766 Meter reading value shall be less than 1 Ω
Earth Electrode Resistance Test
i To test the earth electrode resistance
70 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
ii To ascertain the suitability of the location of the electrode
iii To ensure that the electrode is not buried within the resistance area of another electrode
iv Test equipment ndash Earth Resistance Tester
v Test method -
1 1048766 Terminal rsquoErsquo is connected to the electrode to be tested (green conductor)
2 1048766 Terminal lsquoPrsquo is connected to the potential spike (yellow conductor) at a distance of 10
meters from the earth electrode
3 1048766 Terminal lsquoCrsquo is connected to the current spike (red conductor) at a distance of 20 meters
from the earth electrode E P C Electrode 10 meter 10 meter
Figure 86 ndash Earth Electrode Resistance Measurement Test Equipment
Earth Electrode Resistance Measurement Method (Figure 86)
This test must be repeated at least three times to ensure that the reading is not affected by interacting
earthing regions
i Record the first reading (Z1) Example Z1 = 10 Ω
ii Move the voltage spike to a distance of 6 meters from the original position Record the second
reading (Z2) Example Z2 = 10 Ω
iii Move the voltage spike to a distance of 6 meters from the original position Record the third
reading (Z3)
Example Z3 = 10 Ω
Residual Current Device Test
71 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
i Ensure that the residual current device (RCD) trips within the set time on the occurrence of current
leakage to earth
ii Test Equipment ndash RCD Tester RCCB Tester
iii Test Method 1
1 1048766 Use the Trip Test Button
2 1048766 Press the trip button found on the RCD to determine if it trips or otherwise This test would
not be able to determine the sensitivity of the RCD nor the time taken for it to trip
iv Test Method 2
1048766 Use a RCD Tester
This equipment is equipped with a 13A plug which can be connected to a 13A socket outlet Select the
RCD sensitivity to be the same as the sensitivity of the RCD to be tested to determine if the RCD can
trip The time to trip shall not exceed 40 mS
1048766 Test method ndash
a) Position the selection switch in accordance with the sensitivity of the RCD used
Example 100 mA 01 A
b) Position the operations switch to lsquoNo Triprsquo (frac12 Rated mA = 50) connect the 3 pin plug to
the 13A socket outlet
c) Switch on the 13A socket outlet ndash ensure that the P-N and P-E lights light up This shows that
the polarity is correct (Note if both the lights as above do not light up the test cannot be
continued)
d) Press the test button ndash the reading shows less than 200 millisecond and simultaneously the
lsquotestrsquo light lights up and the P-N and P-E lights do not light up At that instant the RCD will
not trip
e) Move the selection switch to 180o (+ve wave) ndash repeat steps (d) and (e) = 100)
f) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
g) Move the selection switch to 0o (-ve wave)
h) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
i) The above test is repeated until a near correct reading is obtained
j) Record the test results
k) Change the operations switch to lsquoFast Triprsquo and press the test button ndash RCD will trip within a
time not exceeding 40 mS
l) Repeat a number of times at 0o or 180o
72 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 9 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (DC)
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
73 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Start stop button 240Vac 5A 2
9 Filament lamp (Bulb ) 240Vac 40W 3
10 Overload Relay 415V 20A 3
11 Three phase induction motor 5 hp 3
12 Single phase step down transformer 2500VA 1
13 Single core PVC insulated Cable 1mm 2 As required
14 Single core PVC insulated Cable 25mm 2 As required
15 DIN rail 35 mm As required
16 PVC type Cable tray 50 mm x 50 mm As required
17 Cable ties 4 ldquo As required
18 Flexible wires 05 mm As required
19 PVC Connectors 5 A amp 20 A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the schematic
diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a optional exercise
i Simple DOL starter
ii Forward reverse DOL starter
iii Forward Reverse Dahlander motor
iv Three motors operated in sequence by DOL starter operated by manual push
button or time delay relay
74 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
a One loop per-cycle
b Continuous operation in a loop
c optional circuit design to represent the same task
v Only one out of three motors to be operated at a time (quiz)
4 Test the functionality of completed project
LESSON 10 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (AC)
75 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 1
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Lamp point 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
76 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
11 Overload Relay 415V 20A 3
12 Three phase induction
motor
5 hp 3
13 Single core PVC insulated
Cable
1mm 2 As required
14 Single core PVC insulated
Cable
25mm 2 As required
15 DIN rail 35 mm As required
16 PVC type Cable tray 50 mm x 50 mm As required
17 Cable ties 4 ldquo As required
18 Flexible wires 05 mm As required
19 PVC Connectors 5 A amp 20 A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the
schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram optional exercise
4 Simple DOL starter
5 Forward reverse DOL starter
6 Test the functionality of completed project
77 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 1
78 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
cm
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Indicating light 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
11 Overload Relay 415V 20A 3
12 Three phase induction motor 5 hp 3
13 Single phase step down
transformer
2500VA 1
14 Single core PVC insulated
Cable
1mm 2 As required
15 Single core PVC insulated
Cable
25mm 2 As required
16 DIN rail 35 mm As required
17 PVC type Cable tray 50 mm x 50 mm As required
18 Cable ties 4 ldquo As required
19 Flexible wires 05 mm As required
20 PVC Connectors 5 A amp 20 A 240 V As required
21 Single pole MCB 6A 240 V 1
22 Single pole MCB 2A 240 V 1
23 Triple pole MCB 20A 415 V 1
24 Mounting board 30 cm x 40 cm x 3
cm
1
25 Relay cw 11 pin socket 10 A 240 Vac 2
26 Time delay relay 10 A 240 Vac 3
27 Triple pole Contactor 20A 240Vac 3
28 Batten type Lamp holder 240Vac 10 A 3
29 Start stop button 240Vac 10A 2
30 Indicating light (Bulb ) 240Vac 25W 3
31 Overload Relay 415V 20A 1
32 Three phase dahlander type
induction motor
5 hp 1
33 Single phase step down
transformer
24024Vac
2500VA
1
79 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
34 Single core PVC insulated
Cable
1mm 2 As required
35 Single core PVC insulated
Cable
25mm 2 As required
36 DIN rail 35 mm As required
37 PVC type Cable tray 50 mm x 50 mm As required
38 Cable ties 4 ldquo As required
39 Flexible wires 075 mm As required
40 PVC Connectors 5 A amp 20 A 240 V As required
41 Terminal block 20A 240Vac As required
Procedures
5 Identify each component according to specification and quantity required from the schematic
diagram attached
6 Test the functionality of each component by using multi-meter or power supply whichever
applicable
7 Wire component according to circuit diagram
8 Three motors operated in sequence by DOL starter operated by manual push button or time
delay relay
a One loop per-cycle
b Continuous operation in a loop
c optional circuit design to represent the same task
d Only one out of three motors to be operated at a time (quiz)
9 Test the functionality of completed project
80 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
BASIC DESIGN INDUSTRIAL MOTOR CONTROL (SEQUENCE CONTROL)
THREE PHASE INDUCTION MOTOR OPERATED IN SEQUENCE BY DIRECT ON LINE
STARTER
LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
81 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
82 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Lcd lamp indicator 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
11 Overload Relay 415V 20A 3
12 Three phase induction motor 5 hp 3
13 Single phase step down transformer 2500VA 1
14 Single core PVC insulated Cable 1mm 2 As required
15 Single core PVC insulated Cable 25mm 2 As required
16 DIN rail 35 mm As required
17 PVC type Cable tray 50 mm x 50 mm As required
18 Cable ties 4 ldquo As required
19 Flexible wires 1 mm Oslash As required
20 PVC Terminal block 10A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the schematic
diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a optional exercise
i Forward Reverse dahlander motor
4 Test the functionality of completed project
83 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
THREE PHASE DAHLANDER TYPE INDUCTION MOTOR OPERATED FORWARD AND
REVERSE OPERATION BY DIRECT ON LINE STARTER
84 ndash 99EASYTECH ENTERPRISE
LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
Introduction
If a motors windings are connected in the star configuration any two phases will be in series across
the supply and hence the line current will be smaller(by 577) than if the windings were connected in
the delta arrangement
Hence larger-type motors with heavy starting currents are first connected in star and then when the
starting currents fall in delta This of course means that all six of the ends of the windings must be
brought to terminations outside the casing (Fig 833)
EZTECH
EZTECH ELECTRICAL INSTALLATION GUIDE
The automatic version of this starter incorporates a timing relay which automatically changes the
connections from star to delta Figs 834 and 835 show the wiring and schematic diagrams for a star
delta starter
Objectives
1 Identify component and the specification
2 Design forward reverse star delta starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
2 ndash 99EASYTECH ENTERPRISE
REV -C
LEGENDMCCB Moulded Case Circuit BreakerTOR Thermal Over Load RelayFOW-C Mains Forward ContactorREV-C Mains Reverse ContactorDC Delta ContactorSC Star ContactorS-SW Mains Selector Switch
SC
V2
W2
U2
DC
V1
W1
U1
TOR
TOR
FOW-C
30A MCCB
TOR
MAIN CIRCUIT FORWARD REVERSE STAR DELTA
RYBN S
-SW
3 PHASEINDUCTION MOTOR
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Relay 10 A 240V 3
5 Triple pole Contactor
6 cw NO NC auxiliary contact
240Vac 20 A 4
7 Overload Relay 415 V 1
8 LED indicator 240vac 5 A 4
9 Start stop button 240Vac 5A 2
10 DIN rail 35 mm As required
11 Flexible wires 1 mm As required
12 Single core PVC insulated
wire
25 mm As required
13 Terminal block 20 A As required
14 Squirrel cage motor 5kW 1
15 5 pin plug and socket 415V 20A 1
16 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
3 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
a Manual star delta
b Manual Forward reverse star delta starter
c Automatic star delta starter
d Automatic Forward reverse star delta starter
4 Test the functionality of completed project
4 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
Objectives
1 Identify component and the specification
2 Design auto transformer starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
5 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Autotransformer starter is used to start a 3 phase induction motor that has a rating between 10 to 15 hp
6 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Autotransformer set 10Kw 415 V 50 Hz 1
5 Triple pole Contactor 240Vac 4
6 Batten type Lamp holder 240 Vac 105 A 4
7 Start stop button 240Vac 10A 4
8 Filament lamp (Bulb ) 240Vac 40W 4
9 DIN rail 35 mm As required
10 Flexible wires 1 mm As required
7 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
11 Single core PVC insulated
wire
25 mm As required
12 Terminal block 20 A As required
13 Squirrel cage motor 10kW 1
14 5 pin plug and socket 415V 20A 1
15 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a open transient autotransformer starter
b close transient autotransformer starter
c Forward reverse autotransformer starter
4 Test the functionality of completed project
8 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
Objectives
1 Identify component and the specification
2 Design rotor resistance starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
9 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Rotor Resistor set 10kW 1
5 Triple pole Contactor 240Vac 20A 4
6 Indicating light 240vac 5 A 4
7 Start stop push button 240Vac 5A 4
8 DIN rail 35 mm As required
9 Flexible wires 1 mm 2 As required
10 Single core PVC insulated wire 25 mm 2 As required
11 Terminal block 20 A As required
12 Slip Ring motor 10kW 1
13 5 pin round 3 phase socket 415V 20A 1
14 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
10 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
4 Test the functionality of completed project
a Dead circuit test b Life circuit test
5 Measure starting and running Amps
LESSON 16
TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
An installation in general will suffer damage
Damage usually occurs on the electric motor control as follows
1 Damage to the main circuit
2 Damage to the control circuit
The cause of the damage
i Overcurrent overload short circuit
ii Leakage current to ground
iii Equipment malfunction
iv The main control circuit
a Trip of main circuit protection devices fire
b Defect of motor terminal such as short circuit fire loose
v The control circuit is not functioning -
a contactor relay relay time overload relay does not work damaged burned
b Loose cable connection disconnected
Detecting and Repairing Damage
Examples of damage are as follows
i Motor does not work
ii Motor function and overload relay trips
iii Motor function but only partially functional control circuit
Methods of detecting damage
Among the known methods necessary to detect damage are as follows
1 Turn off the electricity at the main switch (main switch) in order to avoid any danger during the
work carried out to detect damage
2 Check all the protective gear that controls the motor control main circuit
11 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
3 Make sure the damage function control circuit
4 Check the control circuit according to the schematic circuit diagram of the motor control
5 Check the operation of the control circuit
Note
Use wiring that has been installed on the SYSTEM OF MOTOR CONTROL BOARD by Forward
Reverse control circuit for Star Delta to test and look for damage
SELF-ASSESSMENT QUESTIONS
1 (a) Explain what is meant by the term lsquoback emfrsquo in a motor
(b) Outline the basic differences between series shunt and compound wound dc motors
2 (a) With the aid of diagrams explain how the speed of series shunt and compound-wound motors
may be controlled
(b) A 440V dc shunt-wound motor has a field resistance of 200R and an armature resistance of 06 R
When its speed is 20 rev d second the current drawn from the supply is 122A Calculate its back
emf at this speed If the speed were decreased to 19 revssecond the field flux remaining unchanged
calculate the new back emf and the new armature current
3 A load of 64 kW at 240 V is supplied from the terminals of a shunt-wound dc generator The field
resistance is 180 A Calculate the armature current
4 (a) Explain with the aid of a diagram how a rotating magnetic field may be
(b) What is meant by lsquosynchronous speedrsquo
Calculate the synchronous obtained speed of a 12 pole motor if the supply frequency is 50Hz
5 (a) Explain the action of a synchronous motor
(b) What methods are available to start a synchronous motor Explain with diagrams
6 (a) Explain the action of a cage induction motor
(b) What is meant by the term lsquosliprsquo
Calculate the percentage slip of a six pole induction motor running at 162 revssecond from a 50 Hz
supply
7 Describe with sketches three different ways of starting a single-phase induction motor
12 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
8 Explain with the aid of a sketch the action of a three-phase DOL starter
What are dashpots used for How are remote start and stop buttons connected
9 A I0 kW 240V 50Hz single-phase cage rotor induction motor is 85efficient and has a PF of 068
lagging Calculate the motor current and the value of capacitor required to raise the PF to 093
lagging
10 Calculate the torque developed by an 18 kW four-pole induction motor run at 35 slip from a
50Hz supply
APPENDIX 1
13 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 11
14 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 111
Attachment Reference
httpswwwtlc-directcoukBook621htm
httpwwwstgovmyindexphpms
15 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
bull Test Method
1 1048766 Ensure that the main switch RCD and MCB are open circuited (switched off) and all loads
are disconnected
2 1048766 Connected the test leads as in the Figure 81 The meter reading shall be less than 1 Ω
55 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Final Ring Circuit Conductor Continuity Test
bull To ensure that all conductors around the ring circuit have continuity
bull Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
bull Test Method
1 1048766 Disconnect both the supply source live conductors from the MCB the neutral conductor
from the neutral terminals and the earth conductor from the earth terminal in the distribution
fuse box
2 1048766 Connect the test leads as in the Figure 82 (EE)
3 1048766 Repeat the procedure for (L-L) and (N-N)
4 1048766 The meter reading value shall be less than 1 ohm
56 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Live and Neutral Conductor Continuity Test
a To ensure that each conductor in the circuit has continuity
b Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
2 Test Method
1 1048766 Switch off the Main switch RCD and MCB
2 1048766 Disconnect all loads
3 1048766 Switch on all switches in the circuit
4 1048766 Disconnect the fusesfinal circuit breakers and close the circuit
5 1048766 Carry out the test as shown in Figure 83
6 1048766 The meter reading value shall be less than 1Ω
57 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
58 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
CONTINUITY TEST
Insulation Resistance Test
i Ensure that there is no leakage current between phase conductors phase and neutral conductors and
phase conductor and earth
ii Test the strength of the cable insulation
iii Test Equipment ndash Insulation Resistance Tester operating voltage is 250VDC or 500VDC
iv Test Method
1 1048766 Switch off main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
59 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
4 1048766 Carry out test as in the Table below
5 1048766 Meter reading value shall be less than 1 Megaohm
60 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
61 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Insulation resitance test
62 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
INSULATION RESISTANCE TEST BETWEEN CONDUCTORS AND OPPOSITE POLARITY
Polarity Testi Ensure that each fuse or single pole control and protection device is connected only in the phase
conductor
ii Intermediate contact of Edison screw lamp holder is connected to the phase conductor
iii Ensure that phase neutral and earth conductors at socket outlets are connected at the correct
terminals
iv Test Equipment ndash Multimeter (Ohm range) or Ohm meter
v Test Method
1 1048766 Switch off Main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in Figure 85
63 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
5 1048766 Test switches and single phase control devices at the phase conductors
6 1048766 Test socket outlet connection sources
7 1048766 Test Edison screw lamp holder connections
8 1048766 Meter reading value shall be less than 1 Ω
64 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Polarity test
65 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Earth Electrode Resistance Testi To test the earth electrode resistance
ii To ascertain the suitability of the location of the electrode
iii To ensure that the electrode is not buried within the resistance area of another electrode
iv Test equipment ndash Earth Resistance Tester
v Test method -
1 1048766 Terminal rsquoErsquo is connected to the electrode to be tested (green conductor)
2 1048766 Terminal lsquoPrsquo is connected to the potential spike (yellow conductor) at a distance of 10
meters from the earth electrode
3 1048766 Terminal lsquoCrsquo is connected to the current spike (red conductor) at a distance of 20 meters
from the earth electrode
Earth Electrode Resistance Measurement Method (Figure 86)
This test must be repeated at least three times to ensure that the reading is not affected by interacting
earthing regions
i Record the first reading (Z1) Example Z1 = 10 Ω
ii Move the voltage spike to a distance of 6 meters from the original position Record the second
reading (Z2 ) Example Z2 = 10 Ω
iii Move the voltage spike to a distance of 6 meters from the original position Record the third
reading (Z3) Example Z3 = 10 Ω
66 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Residual Current Device Testi Ensure that the residual current device (RCD) trips within the set time on the occurrence of current
leakage to earth
ii Test Equipment ndash RCD Tester RCCB Tester
iii Test Method 1
1 1048766 Use the Trip Test Button
2 1048766 Press the trip button found on the RCD to determine if it trips or otherwise This test would
not be able to determine the sensitivity of the RCD nor the time taken for it to trip
iv Test Method 2
i 1048766 Use a RCD Tester
ii This equipment is equipped with a 13A plug which can be connected to a 13A socket outlet
Select the RCD sensitivity to be the same as the sensitivity of the RCD to be tested to
determine if the RCD can trip The time to trip shall not exceed 40 mS
iii 1048766 Test method ndash
a) Position the selection switch in accordance with the sensitivity of the RCD used
Example 100 mA 01 A
b) Position the operations switch to lsquoNo Triprsquo (frac12 Rated mA = 50) connect the 3 pin plug to
the 13A socket outlet
67 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
c) Switch on the 13A socket outlet ndash ensure that the P-N and P-E lights light up
This shows that the polarity is correct (Note if both the lights as above do not light up the test cannot
be continued)
d) Press the test button ndash the reading shows less than 200 mS and simultaneously the lsquotestrsquo light lights
up and the P-N and P-E lights do not light up At that instant the RCD will not trip
e) Move the selection switch to 180o (+ve wave) ndash repeat steps (d) and (e) Move the operations
switch to lsquoTriprsquo (Rated mA = 100)
g) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200mS
h) Move the selection switch to 0o (-ve wave)
i) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
j) The above test is repeated until a near correct reading is obtained
k) Record the test results
l) Change the operations switch to lsquoFast Triprsquo and press the test button ndash RCD will trip within a
time not exceeding 40 millisecond
m) Repeat a number of times at 0o or 180o
On completion of a wiring installation a number of tests on the installation have to be conducted to
ascertain that the wiring circuits and connected appliances are safe for use Prior to carrying out the
tests an inspection has to be done the following tests shall be conducted
i Continuity Test
ii Insulation Resistance Test
iii Polarity Test
iv Earth Electrode Resistance test and
v Residual Current Device Test
821 Continuity Test
There are 3 main types of continuity tests for the final circuits-
i Protection Conductor Continuity Test
ii Final Ring Circuit Conductor Continuity Test
68 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
iii Live and Neutral Conductor Continuity Test
a) Protection Conductor Continuity Test
bull To ascertain that all protection conductors are connected in the correct and effective manner
bull Test equipment ndash Multimeter (Ohm range) or Ohm meter
bull Test Method
1 1048766 Ensure that the main switch RCD and MCB are open circuited (switched off) and all loads are
disconnected
2 1048766 Connected the test leads as in the Figure 81
3 1048766 The meter reading shall be less than 1 Ω
Final Ring Circuit Conductor Continuity Test
bull To ensure that all conductors around the ring circuit have continuity
bull Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
bull Test Method
1 1048766 Disconnect both the supply source live conductors from the MCB the neutral conductor
from the neutral terminals and the earth conductor from the earth terminal in the distribution
fuse box
2 1048766 Connect the test leads as in the Figure 82 (EE)
3 1048766 Repeat the procedure for (L-L) and (N-N)
4 1048766 The meter reading value shall be less than 1 ohm Figure 82 - Final Ring Circuit Conductor
Continuity Test Ohm Meter
Disconnect both the supply source cables from mcbfuse
Take readings at earth conductors of both sources and note resistance readings
Live and Neutral Conductor Continuity Test
1 To ensure that each conductor in the circuit has continuity
2 Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
3 Test Method
1 1048766 Switch off the Main switch RCD and MCB
2 1048766 Disconnect all loads
3 1048766 Switch on all switches in the circuit
4 1048766 Disconnect the fusesfinal circuit breakers and close the circuit
5 1048766 Carry out the test as shown in Figure 83
6 1048766 The meter reading value shall be less than 1 ohm Figure 83 - Live and Neutral
Conductor Continuity Test Ohm Meter
Insulation Resistance Test
69 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
i Ensure that there is no leakage current between phase conductors phase and neutral conductors and
phase conductor and earth
ii Test the strength of the cable insulation
iii Test Equipment ndash Insulation Resistance Tester Operating voltage is 250VDC or 500VDC
iv Test Method
1 1048766 Switch off main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in the Table below
5 1048766 Meter reading value shall be less than 1 Megaohm
Polarity Test
i Ensure that each fuse or single pole control and protection device is connected only in the phase
conductor
ii Intermediate contact of Edison screw lamp holder is connected to the phase conductor
iii Ensure that phase neutral and earth conductors at socket outlets are connected at the correct
terminals
iv Test Equipment ndash Multimeter (Ohm range) or Ohm meter
v Test Method
1 1048766 Switch off Main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in Figure 85
5 1048766 Test switches and single phase control devices at the phase conductors
6 1048766 Test socket outlet connection sources
7 1048766 Test Edison screw lamp holder connections
8 1048766 Meter reading value shall be less than 1 Ω
Earth Electrode Resistance Test
i To test the earth electrode resistance
70 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
ii To ascertain the suitability of the location of the electrode
iii To ensure that the electrode is not buried within the resistance area of another electrode
iv Test equipment ndash Earth Resistance Tester
v Test method -
1 1048766 Terminal rsquoErsquo is connected to the electrode to be tested (green conductor)
2 1048766 Terminal lsquoPrsquo is connected to the potential spike (yellow conductor) at a distance of 10
meters from the earth electrode
3 1048766 Terminal lsquoCrsquo is connected to the current spike (red conductor) at a distance of 20 meters
from the earth electrode E P C Electrode 10 meter 10 meter
Figure 86 ndash Earth Electrode Resistance Measurement Test Equipment
Earth Electrode Resistance Measurement Method (Figure 86)
This test must be repeated at least three times to ensure that the reading is not affected by interacting
earthing regions
i Record the first reading (Z1) Example Z1 = 10 Ω
ii Move the voltage spike to a distance of 6 meters from the original position Record the second
reading (Z2) Example Z2 = 10 Ω
iii Move the voltage spike to a distance of 6 meters from the original position Record the third
reading (Z3)
Example Z3 = 10 Ω
Residual Current Device Test
71 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
i Ensure that the residual current device (RCD) trips within the set time on the occurrence of current
leakage to earth
ii Test Equipment ndash RCD Tester RCCB Tester
iii Test Method 1
1 1048766 Use the Trip Test Button
2 1048766 Press the trip button found on the RCD to determine if it trips or otherwise This test would
not be able to determine the sensitivity of the RCD nor the time taken for it to trip
iv Test Method 2
1048766 Use a RCD Tester
This equipment is equipped with a 13A plug which can be connected to a 13A socket outlet Select the
RCD sensitivity to be the same as the sensitivity of the RCD to be tested to determine if the RCD can
trip The time to trip shall not exceed 40 mS
1048766 Test method ndash
a) Position the selection switch in accordance with the sensitivity of the RCD used
Example 100 mA 01 A
b) Position the operations switch to lsquoNo Triprsquo (frac12 Rated mA = 50) connect the 3 pin plug to
the 13A socket outlet
c) Switch on the 13A socket outlet ndash ensure that the P-N and P-E lights light up This shows that
the polarity is correct (Note if both the lights as above do not light up the test cannot be
continued)
d) Press the test button ndash the reading shows less than 200 millisecond and simultaneously the
lsquotestrsquo light lights up and the P-N and P-E lights do not light up At that instant the RCD will
not trip
e) Move the selection switch to 180o (+ve wave) ndash repeat steps (d) and (e) = 100)
f) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
g) Move the selection switch to 0o (-ve wave)
h) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
i) The above test is repeated until a near correct reading is obtained
j) Record the test results
k) Change the operations switch to lsquoFast Triprsquo and press the test button ndash RCD will trip within a
time not exceeding 40 mS
l) Repeat a number of times at 0o or 180o
72 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 9 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (DC)
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
73 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Start stop button 240Vac 5A 2
9 Filament lamp (Bulb ) 240Vac 40W 3
10 Overload Relay 415V 20A 3
11 Three phase induction motor 5 hp 3
12 Single phase step down transformer 2500VA 1
13 Single core PVC insulated Cable 1mm 2 As required
14 Single core PVC insulated Cable 25mm 2 As required
15 DIN rail 35 mm As required
16 PVC type Cable tray 50 mm x 50 mm As required
17 Cable ties 4 ldquo As required
18 Flexible wires 05 mm As required
19 PVC Connectors 5 A amp 20 A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the schematic
diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a optional exercise
i Simple DOL starter
ii Forward reverse DOL starter
iii Forward Reverse Dahlander motor
iv Three motors operated in sequence by DOL starter operated by manual push
button or time delay relay
74 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
a One loop per-cycle
b Continuous operation in a loop
c optional circuit design to represent the same task
v Only one out of three motors to be operated at a time (quiz)
4 Test the functionality of completed project
LESSON 10 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (AC)
75 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 1
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Lamp point 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
76 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
11 Overload Relay 415V 20A 3
12 Three phase induction
motor
5 hp 3
13 Single core PVC insulated
Cable
1mm 2 As required
14 Single core PVC insulated
Cable
25mm 2 As required
15 DIN rail 35 mm As required
16 PVC type Cable tray 50 mm x 50 mm As required
17 Cable ties 4 ldquo As required
18 Flexible wires 05 mm As required
19 PVC Connectors 5 A amp 20 A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the
schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram optional exercise
4 Simple DOL starter
5 Forward reverse DOL starter
6 Test the functionality of completed project
77 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 1
78 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
cm
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Indicating light 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
11 Overload Relay 415V 20A 3
12 Three phase induction motor 5 hp 3
13 Single phase step down
transformer
2500VA 1
14 Single core PVC insulated
Cable
1mm 2 As required
15 Single core PVC insulated
Cable
25mm 2 As required
16 DIN rail 35 mm As required
17 PVC type Cable tray 50 mm x 50 mm As required
18 Cable ties 4 ldquo As required
19 Flexible wires 05 mm As required
20 PVC Connectors 5 A amp 20 A 240 V As required
21 Single pole MCB 6A 240 V 1
22 Single pole MCB 2A 240 V 1
23 Triple pole MCB 20A 415 V 1
24 Mounting board 30 cm x 40 cm x 3
cm
1
25 Relay cw 11 pin socket 10 A 240 Vac 2
26 Time delay relay 10 A 240 Vac 3
27 Triple pole Contactor 20A 240Vac 3
28 Batten type Lamp holder 240Vac 10 A 3
29 Start stop button 240Vac 10A 2
30 Indicating light (Bulb ) 240Vac 25W 3
31 Overload Relay 415V 20A 1
32 Three phase dahlander type
induction motor
5 hp 1
33 Single phase step down
transformer
24024Vac
2500VA
1
79 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
34 Single core PVC insulated
Cable
1mm 2 As required
35 Single core PVC insulated
Cable
25mm 2 As required
36 DIN rail 35 mm As required
37 PVC type Cable tray 50 mm x 50 mm As required
38 Cable ties 4 ldquo As required
39 Flexible wires 075 mm As required
40 PVC Connectors 5 A amp 20 A 240 V As required
41 Terminal block 20A 240Vac As required
Procedures
5 Identify each component according to specification and quantity required from the schematic
diagram attached
6 Test the functionality of each component by using multi-meter or power supply whichever
applicable
7 Wire component according to circuit diagram
8 Three motors operated in sequence by DOL starter operated by manual push button or time
delay relay
a One loop per-cycle
b Continuous operation in a loop
c optional circuit design to represent the same task
d Only one out of three motors to be operated at a time (quiz)
9 Test the functionality of completed project
80 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
BASIC DESIGN INDUSTRIAL MOTOR CONTROL (SEQUENCE CONTROL)
THREE PHASE INDUCTION MOTOR OPERATED IN SEQUENCE BY DIRECT ON LINE
STARTER
LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
81 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
82 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Lcd lamp indicator 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
11 Overload Relay 415V 20A 3
12 Three phase induction motor 5 hp 3
13 Single phase step down transformer 2500VA 1
14 Single core PVC insulated Cable 1mm 2 As required
15 Single core PVC insulated Cable 25mm 2 As required
16 DIN rail 35 mm As required
17 PVC type Cable tray 50 mm x 50 mm As required
18 Cable ties 4 ldquo As required
19 Flexible wires 1 mm Oslash As required
20 PVC Terminal block 10A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the schematic
diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a optional exercise
i Forward Reverse dahlander motor
4 Test the functionality of completed project
83 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
THREE PHASE DAHLANDER TYPE INDUCTION MOTOR OPERATED FORWARD AND
REVERSE OPERATION BY DIRECT ON LINE STARTER
84 ndash 99EASYTECH ENTERPRISE
LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
Introduction
If a motors windings are connected in the star configuration any two phases will be in series across
the supply and hence the line current will be smaller(by 577) than if the windings were connected in
the delta arrangement
Hence larger-type motors with heavy starting currents are first connected in star and then when the
starting currents fall in delta This of course means that all six of the ends of the windings must be
brought to terminations outside the casing (Fig 833)
EZTECH
EZTECH ELECTRICAL INSTALLATION GUIDE
The automatic version of this starter incorporates a timing relay which automatically changes the
connections from star to delta Figs 834 and 835 show the wiring and schematic diagrams for a star
delta starter
Objectives
1 Identify component and the specification
2 Design forward reverse star delta starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
2 ndash 99EASYTECH ENTERPRISE
REV -C
LEGENDMCCB Moulded Case Circuit BreakerTOR Thermal Over Load RelayFOW-C Mains Forward ContactorREV-C Mains Reverse ContactorDC Delta ContactorSC Star ContactorS-SW Mains Selector Switch
SC
V2
W2
U2
DC
V1
W1
U1
TOR
TOR
FOW-C
30A MCCB
TOR
MAIN CIRCUIT FORWARD REVERSE STAR DELTA
RYBN S
-SW
3 PHASEINDUCTION MOTOR
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Relay 10 A 240V 3
5 Triple pole Contactor
6 cw NO NC auxiliary contact
240Vac 20 A 4
7 Overload Relay 415 V 1
8 LED indicator 240vac 5 A 4
9 Start stop button 240Vac 5A 2
10 DIN rail 35 mm As required
11 Flexible wires 1 mm As required
12 Single core PVC insulated
wire
25 mm As required
13 Terminal block 20 A As required
14 Squirrel cage motor 5kW 1
15 5 pin plug and socket 415V 20A 1
16 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
3 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
a Manual star delta
b Manual Forward reverse star delta starter
c Automatic star delta starter
d Automatic Forward reverse star delta starter
4 Test the functionality of completed project
4 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
Objectives
1 Identify component and the specification
2 Design auto transformer starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
5 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Autotransformer starter is used to start a 3 phase induction motor that has a rating between 10 to 15 hp
6 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Autotransformer set 10Kw 415 V 50 Hz 1
5 Triple pole Contactor 240Vac 4
6 Batten type Lamp holder 240 Vac 105 A 4
7 Start stop button 240Vac 10A 4
8 Filament lamp (Bulb ) 240Vac 40W 4
9 DIN rail 35 mm As required
10 Flexible wires 1 mm As required
7 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
11 Single core PVC insulated
wire
25 mm As required
12 Terminal block 20 A As required
13 Squirrel cage motor 10kW 1
14 5 pin plug and socket 415V 20A 1
15 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a open transient autotransformer starter
b close transient autotransformer starter
c Forward reverse autotransformer starter
4 Test the functionality of completed project
8 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
Objectives
1 Identify component and the specification
2 Design rotor resistance starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
9 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Rotor Resistor set 10kW 1
5 Triple pole Contactor 240Vac 20A 4
6 Indicating light 240vac 5 A 4
7 Start stop push button 240Vac 5A 4
8 DIN rail 35 mm As required
9 Flexible wires 1 mm 2 As required
10 Single core PVC insulated wire 25 mm 2 As required
11 Terminal block 20 A As required
12 Slip Ring motor 10kW 1
13 5 pin round 3 phase socket 415V 20A 1
14 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
10 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
4 Test the functionality of completed project
a Dead circuit test b Life circuit test
5 Measure starting and running Amps
LESSON 16
TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
An installation in general will suffer damage
Damage usually occurs on the electric motor control as follows
1 Damage to the main circuit
2 Damage to the control circuit
The cause of the damage
i Overcurrent overload short circuit
ii Leakage current to ground
iii Equipment malfunction
iv The main control circuit
a Trip of main circuit protection devices fire
b Defect of motor terminal such as short circuit fire loose
v The control circuit is not functioning -
a contactor relay relay time overload relay does not work damaged burned
b Loose cable connection disconnected
Detecting and Repairing Damage
Examples of damage are as follows
i Motor does not work
ii Motor function and overload relay trips
iii Motor function but only partially functional control circuit
Methods of detecting damage
Among the known methods necessary to detect damage are as follows
1 Turn off the electricity at the main switch (main switch) in order to avoid any danger during the
work carried out to detect damage
2 Check all the protective gear that controls the motor control main circuit
11 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
3 Make sure the damage function control circuit
4 Check the control circuit according to the schematic circuit diagram of the motor control
5 Check the operation of the control circuit
Note
Use wiring that has been installed on the SYSTEM OF MOTOR CONTROL BOARD by Forward
Reverse control circuit for Star Delta to test and look for damage
SELF-ASSESSMENT QUESTIONS
1 (a) Explain what is meant by the term lsquoback emfrsquo in a motor
(b) Outline the basic differences between series shunt and compound wound dc motors
2 (a) With the aid of diagrams explain how the speed of series shunt and compound-wound motors
may be controlled
(b) A 440V dc shunt-wound motor has a field resistance of 200R and an armature resistance of 06 R
When its speed is 20 rev d second the current drawn from the supply is 122A Calculate its back
emf at this speed If the speed were decreased to 19 revssecond the field flux remaining unchanged
calculate the new back emf and the new armature current
3 A load of 64 kW at 240 V is supplied from the terminals of a shunt-wound dc generator The field
resistance is 180 A Calculate the armature current
4 (a) Explain with the aid of a diagram how a rotating magnetic field may be
(b) What is meant by lsquosynchronous speedrsquo
Calculate the synchronous obtained speed of a 12 pole motor if the supply frequency is 50Hz
5 (a) Explain the action of a synchronous motor
(b) What methods are available to start a synchronous motor Explain with diagrams
6 (a) Explain the action of a cage induction motor
(b) What is meant by the term lsquosliprsquo
Calculate the percentage slip of a six pole induction motor running at 162 revssecond from a 50 Hz
supply
7 Describe with sketches three different ways of starting a single-phase induction motor
12 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
8 Explain with the aid of a sketch the action of a three-phase DOL starter
What are dashpots used for How are remote start and stop buttons connected
9 A I0 kW 240V 50Hz single-phase cage rotor induction motor is 85efficient and has a PF of 068
lagging Calculate the motor current and the value of capacitor required to raise the PF to 093
lagging
10 Calculate the torque developed by an 18 kW four-pole induction motor run at 35 slip from a
50Hz supply
APPENDIX 1
13 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 11
14 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 111
Attachment Reference
httpswwwtlc-directcoukBook621htm
httpwwwstgovmyindexphpms
15 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Final Ring Circuit Conductor Continuity Test
bull To ensure that all conductors around the ring circuit have continuity
bull Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
bull Test Method
1 1048766 Disconnect both the supply source live conductors from the MCB the neutral conductor
from the neutral terminals and the earth conductor from the earth terminal in the distribution
fuse box
2 1048766 Connect the test leads as in the Figure 82 (EE)
3 1048766 Repeat the procedure for (L-L) and (N-N)
4 1048766 The meter reading value shall be less than 1 ohm
56 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Live and Neutral Conductor Continuity Test
a To ensure that each conductor in the circuit has continuity
b Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
2 Test Method
1 1048766 Switch off the Main switch RCD and MCB
2 1048766 Disconnect all loads
3 1048766 Switch on all switches in the circuit
4 1048766 Disconnect the fusesfinal circuit breakers and close the circuit
5 1048766 Carry out the test as shown in Figure 83
6 1048766 The meter reading value shall be less than 1Ω
57 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
58 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
CONTINUITY TEST
Insulation Resistance Test
i Ensure that there is no leakage current between phase conductors phase and neutral conductors and
phase conductor and earth
ii Test the strength of the cable insulation
iii Test Equipment ndash Insulation Resistance Tester operating voltage is 250VDC or 500VDC
iv Test Method
1 1048766 Switch off main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
59 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
4 1048766 Carry out test as in the Table below
5 1048766 Meter reading value shall be less than 1 Megaohm
60 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
61 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Insulation resitance test
62 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
INSULATION RESISTANCE TEST BETWEEN CONDUCTORS AND OPPOSITE POLARITY
Polarity Testi Ensure that each fuse or single pole control and protection device is connected only in the phase
conductor
ii Intermediate contact of Edison screw lamp holder is connected to the phase conductor
iii Ensure that phase neutral and earth conductors at socket outlets are connected at the correct
terminals
iv Test Equipment ndash Multimeter (Ohm range) or Ohm meter
v Test Method
1 1048766 Switch off Main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in Figure 85
63 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
5 1048766 Test switches and single phase control devices at the phase conductors
6 1048766 Test socket outlet connection sources
7 1048766 Test Edison screw lamp holder connections
8 1048766 Meter reading value shall be less than 1 Ω
64 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Polarity test
65 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Earth Electrode Resistance Testi To test the earth electrode resistance
ii To ascertain the suitability of the location of the electrode
iii To ensure that the electrode is not buried within the resistance area of another electrode
iv Test equipment ndash Earth Resistance Tester
v Test method -
1 1048766 Terminal rsquoErsquo is connected to the electrode to be tested (green conductor)
2 1048766 Terminal lsquoPrsquo is connected to the potential spike (yellow conductor) at a distance of 10
meters from the earth electrode
3 1048766 Terminal lsquoCrsquo is connected to the current spike (red conductor) at a distance of 20 meters
from the earth electrode
Earth Electrode Resistance Measurement Method (Figure 86)
This test must be repeated at least three times to ensure that the reading is not affected by interacting
earthing regions
i Record the first reading (Z1) Example Z1 = 10 Ω
ii Move the voltage spike to a distance of 6 meters from the original position Record the second
reading (Z2 ) Example Z2 = 10 Ω
iii Move the voltage spike to a distance of 6 meters from the original position Record the third
reading (Z3) Example Z3 = 10 Ω
66 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Residual Current Device Testi Ensure that the residual current device (RCD) trips within the set time on the occurrence of current
leakage to earth
ii Test Equipment ndash RCD Tester RCCB Tester
iii Test Method 1
1 1048766 Use the Trip Test Button
2 1048766 Press the trip button found on the RCD to determine if it trips or otherwise This test would
not be able to determine the sensitivity of the RCD nor the time taken for it to trip
iv Test Method 2
i 1048766 Use a RCD Tester
ii This equipment is equipped with a 13A plug which can be connected to a 13A socket outlet
Select the RCD sensitivity to be the same as the sensitivity of the RCD to be tested to
determine if the RCD can trip The time to trip shall not exceed 40 mS
iii 1048766 Test method ndash
a) Position the selection switch in accordance with the sensitivity of the RCD used
Example 100 mA 01 A
b) Position the operations switch to lsquoNo Triprsquo (frac12 Rated mA = 50) connect the 3 pin plug to
the 13A socket outlet
67 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
c) Switch on the 13A socket outlet ndash ensure that the P-N and P-E lights light up
This shows that the polarity is correct (Note if both the lights as above do not light up the test cannot
be continued)
d) Press the test button ndash the reading shows less than 200 mS and simultaneously the lsquotestrsquo light lights
up and the P-N and P-E lights do not light up At that instant the RCD will not trip
e) Move the selection switch to 180o (+ve wave) ndash repeat steps (d) and (e) Move the operations
switch to lsquoTriprsquo (Rated mA = 100)
g) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200mS
h) Move the selection switch to 0o (-ve wave)
i) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
j) The above test is repeated until a near correct reading is obtained
k) Record the test results
l) Change the operations switch to lsquoFast Triprsquo and press the test button ndash RCD will trip within a
time not exceeding 40 millisecond
m) Repeat a number of times at 0o or 180o
On completion of a wiring installation a number of tests on the installation have to be conducted to
ascertain that the wiring circuits and connected appliances are safe for use Prior to carrying out the
tests an inspection has to be done the following tests shall be conducted
i Continuity Test
ii Insulation Resistance Test
iii Polarity Test
iv Earth Electrode Resistance test and
v Residual Current Device Test
821 Continuity Test
There are 3 main types of continuity tests for the final circuits-
i Protection Conductor Continuity Test
ii Final Ring Circuit Conductor Continuity Test
68 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
iii Live and Neutral Conductor Continuity Test
a) Protection Conductor Continuity Test
bull To ascertain that all protection conductors are connected in the correct and effective manner
bull Test equipment ndash Multimeter (Ohm range) or Ohm meter
bull Test Method
1 1048766 Ensure that the main switch RCD and MCB are open circuited (switched off) and all loads are
disconnected
2 1048766 Connected the test leads as in the Figure 81
3 1048766 The meter reading shall be less than 1 Ω
Final Ring Circuit Conductor Continuity Test
bull To ensure that all conductors around the ring circuit have continuity
bull Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
bull Test Method
1 1048766 Disconnect both the supply source live conductors from the MCB the neutral conductor
from the neutral terminals and the earth conductor from the earth terminal in the distribution
fuse box
2 1048766 Connect the test leads as in the Figure 82 (EE)
3 1048766 Repeat the procedure for (L-L) and (N-N)
4 1048766 The meter reading value shall be less than 1 ohm Figure 82 - Final Ring Circuit Conductor
Continuity Test Ohm Meter
Disconnect both the supply source cables from mcbfuse
Take readings at earth conductors of both sources and note resistance readings
Live and Neutral Conductor Continuity Test
1 To ensure that each conductor in the circuit has continuity
2 Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
3 Test Method
1 1048766 Switch off the Main switch RCD and MCB
2 1048766 Disconnect all loads
3 1048766 Switch on all switches in the circuit
4 1048766 Disconnect the fusesfinal circuit breakers and close the circuit
5 1048766 Carry out the test as shown in Figure 83
6 1048766 The meter reading value shall be less than 1 ohm Figure 83 - Live and Neutral
Conductor Continuity Test Ohm Meter
Insulation Resistance Test
69 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
i Ensure that there is no leakage current between phase conductors phase and neutral conductors and
phase conductor and earth
ii Test the strength of the cable insulation
iii Test Equipment ndash Insulation Resistance Tester Operating voltage is 250VDC or 500VDC
iv Test Method
1 1048766 Switch off main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in the Table below
5 1048766 Meter reading value shall be less than 1 Megaohm
Polarity Test
i Ensure that each fuse or single pole control and protection device is connected only in the phase
conductor
ii Intermediate contact of Edison screw lamp holder is connected to the phase conductor
iii Ensure that phase neutral and earth conductors at socket outlets are connected at the correct
terminals
iv Test Equipment ndash Multimeter (Ohm range) or Ohm meter
v Test Method
1 1048766 Switch off Main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in Figure 85
5 1048766 Test switches and single phase control devices at the phase conductors
6 1048766 Test socket outlet connection sources
7 1048766 Test Edison screw lamp holder connections
8 1048766 Meter reading value shall be less than 1 Ω
Earth Electrode Resistance Test
i To test the earth electrode resistance
70 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
ii To ascertain the suitability of the location of the electrode
iii To ensure that the electrode is not buried within the resistance area of another electrode
iv Test equipment ndash Earth Resistance Tester
v Test method -
1 1048766 Terminal rsquoErsquo is connected to the electrode to be tested (green conductor)
2 1048766 Terminal lsquoPrsquo is connected to the potential spike (yellow conductor) at a distance of 10
meters from the earth electrode
3 1048766 Terminal lsquoCrsquo is connected to the current spike (red conductor) at a distance of 20 meters
from the earth electrode E P C Electrode 10 meter 10 meter
Figure 86 ndash Earth Electrode Resistance Measurement Test Equipment
Earth Electrode Resistance Measurement Method (Figure 86)
This test must be repeated at least three times to ensure that the reading is not affected by interacting
earthing regions
i Record the first reading (Z1) Example Z1 = 10 Ω
ii Move the voltage spike to a distance of 6 meters from the original position Record the second
reading (Z2) Example Z2 = 10 Ω
iii Move the voltage spike to a distance of 6 meters from the original position Record the third
reading (Z3)
Example Z3 = 10 Ω
Residual Current Device Test
71 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
i Ensure that the residual current device (RCD) trips within the set time on the occurrence of current
leakage to earth
ii Test Equipment ndash RCD Tester RCCB Tester
iii Test Method 1
1 1048766 Use the Trip Test Button
2 1048766 Press the trip button found on the RCD to determine if it trips or otherwise This test would
not be able to determine the sensitivity of the RCD nor the time taken for it to trip
iv Test Method 2
1048766 Use a RCD Tester
This equipment is equipped with a 13A plug which can be connected to a 13A socket outlet Select the
RCD sensitivity to be the same as the sensitivity of the RCD to be tested to determine if the RCD can
trip The time to trip shall not exceed 40 mS
1048766 Test method ndash
a) Position the selection switch in accordance with the sensitivity of the RCD used
Example 100 mA 01 A
b) Position the operations switch to lsquoNo Triprsquo (frac12 Rated mA = 50) connect the 3 pin plug to
the 13A socket outlet
c) Switch on the 13A socket outlet ndash ensure that the P-N and P-E lights light up This shows that
the polarity is correct (Note if both the lights as above do not light up the test cannot be
continued)
d) Press the test button ndash the reading shows less than 200 millisecond and simultaneously the
lsquotestrsquo light lights up and the P-N and P-E lights do not light up At that instant the RCD will
not trip
e) Move the selection switch to 180o (+ve wave) ndash repeat steps (d) and (e) = 100)
f) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
g) Move the selection switch to 0o (-ve wave)
h) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
i) The above test is repeated until a near correct reading is obtained
j) Record the test results
k) Change the operations switch to lsquoFast Triprsquo and press the test button ndash RCD will trip within a
time not exceeding 40 mS
l) Repeat a number of times at 0o or 180o
72 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 9 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (DC)
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
73 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Start stop button 240Vac 5A 2
9 Filament lamp (Bulb ) 240Vac 40W 3
10 Overload Relay 415V 20A 3
11 Three phase induction motor 5 hp 3
12 Single phase step down transformer 2500VA 1
13 Single core PVC insulated Cable 1mm 2 As required
14 Single core PVC insulated Cable 25mm 2 As required
15 DIN rail 35 mm As required
16 PVC type Cable tray 50 mm x 50 mm As required
17 Cable ties 4 ldquo As required
18 Flexible wires 05 mm As required
19 PVC Connectors 5 A amp 20 A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the schematic
diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a optional exercise
i Simple DOL starter
ii Forward reverse DOL starter
iii Forward Reverse Dahlander motor
iv Three motors operated in sequence by DOL starter operated by manual push
button or time delay relay
74 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
a One loop per-cycle
b Continuous operation in a loop
c optional circuit design to represent the same task
v Only one out of three motors to be operated at a time (quiz)
4 Test the functionality of completed project
LESSON 10 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (AC)
75 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 1
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Lamp point 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
76 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
11 Overload Relay 415V 20A 3
12 Three phase induction
motor
5 hp 3
13 Single core PVC insulated
Cable
1mm 2 As required
14 Single core PVC insulated
Cable
25mm 2 As required
15 DIN rail 35 mm As required
16 PVC type Cable tray 50 mm x 50 mm As required
17 Cable ties 4 ldquo As required
18 Flexible wires 05 mm As required
19 PVC Connectors 5 A amp 20 A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the
schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram optional exercise
4 Simple DOL starter
5 Forward reverse DOL starter
6 Test the functionality of completed project
77 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 1
78 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
cm
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Indicating light 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
11 Overload Relay 415V 20A 3
12 Three phase induction motor 5 hp 3
13 Single phase step down
transformer
2500VA 1
14 Single core PVC insulated
Cable
1mm 2 As required
15 Single core PVC insulated
Cable
25mm 2 As required
16 DIN rail 35 mm As required
17 PVC type Cable tray 50 mm x 50 mm As required
18 Cable ties 4 ldquo As required
19 Flexible wires 05 mm As required
20 PVC Connectors 5 A amp 20 A 240 V As required
21 Single pole MCB 6A 240 V 1
22 Single pole MCB 2A 240 V 1
23 Triple pole MCB 20A 415 V 1
24 Mounting board 30 cm x 40 cm x 3
cm
1
25 Relay cw 11 pin socket 10 A 240 Vac 2
26 Time delay relay 10 A 240 Vac 3
27 Triple pole Contactor 20A 240Vac 3
28 Batten type Lamp holder 240Vac 10 A 3
29 Start stop button 240Vac 10A 2
30 Indicating light (Bulb ) 240Vac 25W 3
31 Overload Relay 415V 20A 1
32 Three phase dahlander type
induction motor
5 hp 1
33 Single phase step down
transformer
24024Vac
2500VA
1
79 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
34 Single core PVC insulated
Cable
1mm 2 As required
35 Single core PVC insulated
Cable
25mm 2 As required
36 DIN rail 35 mm As required
37 PVC type Cable tray 50 mm x 50 mm As required
38 Cable ties 4 ldquo As required
39 Flexible wires 075 mm As required
40 PVC Connectors 5 A amp 20 A 240 V As required
41 Terminal block 20A 240Vac As required
Procedures
5 Identify each component according to specification and quantity required from the schematic
diagram attached
6 Test the functionality of each component by using multi-meter or power supply whichever
applicable
7 Wire component according to circuit diagram
8 Three motors operated in sequence by DOL starter operated by manual push button or time
delay relay
a One loop per-cycle
b Continuous operation in a loop
c optional circuit design to represent the same task
d Only one out of three motors to be operated at a time (quiz)
9 Test the functionality of completed project
80 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
BASIC DESIGN INDUSTRIAL MOTOR CONTROL (SEQUENCE CONTROL)
THREE PHASE INDUCTION MOTOR OPERATED IN SEQUENCE BY DIRECT ON LINE
STARTER
LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
81 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
82 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Lcd lamp indicator 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
11 Overload Relay 415V 20A 3
12 Three phase induction motor 5 hp 3
13 Single phase step down transformer 2500VA 1
14 Single core PVC insulated Cable 1mm 2 As required
15 Single core PVC insulated Cable 25mm 2 As required
16 DIN rail 35 mm As required
17 PVC type Cable tray 50 mm x 50 mm As required
18 Cable ties 4 ldquo As required
19 Flexible wires 1 mm Oslash As required
20 PVC Terminal block 10A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the schematic
diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a optional exercise
i Forward Reverse dahlander motor
4 Test the functionality of completed project
83 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
THREE PHASE DAHLANDER TYPE INDUCTION MOTOR OPERATED FORWARD AND
REVERSE OPERATION BY DIRECT ON LINE STARTER
84 ndash 99EASYTECH ENTERPRISE
LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
Introduction
If a motors windings are connected in the star configuration any two phases will be in series across
the supply and hence the line current will be smaller(by 577) than if the windings were connected in
the delta arrangement
Hence larger-type motors with heavy starting currents are first connected in star and then when the
starting currents fall in delta This of course means that all six of the ends of the windings must be
brought to terminations outside the casing (Fig 833)
EZTECH
EZTECH ELECTRICAL INSTALLATION GUIDE
The automatic version of this starter incorporates a timing relay which automatically changes the
connections from star to delta Figs 834 and 835 show the wiring and schematic diagrams for a star
delta starter
Objectives
1 Identify component and the specification
2 Design forward reverse star delta starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
2 ndash 99EASYTECH ENTERPRISE
REV -C
LEGENDMCCB Moulded Case Circuit BreakerTOR Thermal Over Load RelayFOW-C Mains Forward ContactorREV-C Mains Reverse ContactorDC Delta ContactorSC Star ContactorS-SW Mains Selector Switch
SC
V2
W2
U2
DC
V1
W1
U1
TOR
TOR
FOW-C
30A MCCB
TOR
MAIN CIRCUIT FORWARD REVERSE STAR DELTA
RYBN S
-SW
3 PHASEINDUCTION MOTOR
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Relay 10 A 240V 3
5 Triple pole Contactor
6 cw NO NC auxiliary contact
240Vac 20 A 4
7 Overload Relay 415 V 1
8 LED indicator 240vac 5 A 4
9 Start stop button 240Vac 5A 2
10 DIN rail 35 mm As required
11 Flexible wires 1 mm As required
12 Single core PVC insulated
wire
25 mm As required
13 Terminal block 20 A As required
14 Squirrel cage motor 5kW 1
15 5 pin plug and socket 415V 20A 1
16 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
3 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
a Manual star delta
b Manual Forward reverse star delta starter
c Automatic star delta starter
d Automatic Forward reverse star delta starter
4 Test the functionality of completed project
4 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
Objectives
1 Identify component and the specification
2 Design auto transformer starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
5 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Autotransformer starter is used to start a 3 phase induction motor that has a rating between 10 to 15 hp
6 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Autotransformer set 10Kw 415 V 50 Hz 1
5 Triple pole Contactor 240Vac 4
6 Batten type Lamp holder 240 Vac 105 A 4
7 Start stop button 240Vac 10A 4
8 Filament lamp (Bulb ) 240Vac 40W 4
9 DIN rail 35 mm As required
10 Flexible wires 1 mm As required
7 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
11 Single core PVC insulated
wire
25 mm As required
12 Terminal block 20 A As required
13 Squirrel cage motor 10kW 1
14 5 pin plug and socket 415V 20A 1
15 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a open transient autotransformer starter
b close transient autotransformer starter
c Forward reverse autotransformer starter
4 Test the functionality of completed project
8 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
Objectives
1 Identify component and the specification
2 Design rotor resistance starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
9 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Rotor Resistor set 10kW 1
5 Triple pole Contactor 240Vac 20A 4
6 Indicating light 240vac 5 A 4
7 Start stop push button 240Vac 5A 4
8 DIN rail 35 mm As required
9 Flexible wires 1 mm 2 As required
10 Single core PVC insulated wire 25 mm 2 As required
11 Terminal block 20 A As required
12 Slip Ring motor 10kW 1
13 5 pin round 3 phase socket 415V 20A 1
14 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
10 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
4 Test the functionality of completed project
a Dead circuit test b Life circuit test
5 Measure starting and running Amps
LESSON 16
TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
An installation in general will suffer damage
Damage usually occurs on the electric motor control as follows
1 Damage to the main circuit
2 Damage to the control circuit
The cause of the damage
i Overcurrent overload short circuit
ii Leakage current to ground
iii Equipment malfunction
iv The main control circuit
a Trip of main circuit protection devices fire
b Defect of motor terminal such as short circuit fire loose
v The control circuit is not functioning -
a contactor relay relay time overload relay does not work damaged burned
b Loose cable connection disconnected
Detecting and Repairing Damage
Examples of damage are as follows
i Motor does not work
ii Motor function and overload relay trips
iii Motor function but only partially functional control circuit
Methods of detecting damage
Among the known methods necessary to detect damage are as follows
1 Turn off the electricity at the main switch (main switch) in order to avoid any danger during the
work carried out to detect damage
2 Check all the protective gear that controls the motor control main circuit
11 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
3 Make sure the damage function control circuit
4 Check the control circuit according to the schematic circuit diagram of the motor control
5 Check the operation of the control circuit
Note
Use wiring that has been installed on the SYSTEM OF MOTOR CONTROL BOARD by Forward
Reverse control circuit for Star Delta to test and look for damage
SELF-ASSESSMENT QUESTIONS
1 (a) Explain what is meant by the term lsquoback emfrsquo in a motor
(b) Outline the basic differences between series shunt and compound wound dc motors
2 (a) With the aid of diagrams explain how the speed of series shunt and compound-wound motors
may be controlled
(b) A 440V dc shunt-wound motor has a field resistance of 200R and an armature resistance of 06 R
When its speed is 20 rev d second the current drawn from the supply is 122A Calculate its back
emf at this speed If the speed were decreased to 19 revssecond the field flux remaining unchanged
calculate the new back emf and the new armature current
3 A load of 64 kW at 240 V is supplied from the terminals of a shunt-wound dc generator The field
resistance is 180 A Calculate the armature current
4 (a) Explain with the aid of a diagram how a rotating magnetic field may be
(b) What is meant by lsquosynchronous speedrsquo
Calculate the synchronous obtained speed of a 12 pole motor if the supply frequency is 50Hz
5 (a) Explain the action of a synchronous motor
(b) What methods are available to start a synchronous motor Explain with diagrams
6 (a) Explain the action of a cage induction motor
(b) What is meant by the term lsquosliprsquo
Calculate the percentage slip of a six pole induction motor running at 162 revssecond from a 50 Hz
supply
7 Describe with sketches three different ways of starting a single-phase induction motor
12 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
8 Explain with the aid of a sketch the action of a three-phase DOL starter
What are dashpots used for How are remote start and stop buttons connected
9 A I0 kW 240V 50Hz single-phase cage rotor induction motor is 85efficient and has a PF of 068
lagging Calculate the motor current and the value of capacitor required to raise the PF to 093
lagging
10 Calculate the torque developed by an 18 kW four-pole induction motor run at 35 slip from a
50Hz supply
APPENDIX 1
13 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 11
14 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 111
Attachment Reference
httpswwwtlc-directcoukBook621htm
httpwwwstgovmyindexphpms
15 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Live and Neutral Conductor Continuity Test
a To ensure that each conductor in the circuit has continuity
b Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
2 Test Method
1 1048766 Switch off the Main switch RCD and MCB
2 1048766 Disconnect all loads
3 1048766 Switch on all switches in the circuit
4 1048766 Disconnect the fusesfinal circuit breakers and close the circuit
5 1048766 Carry out the test as shown in Figure 83
6 1048766 The meter reading value shall be less than 1Ω
57 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
58 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
CONTINUITY TEST
Insulation Resistance Test
i Ensure that there is no leakage current between phase conductors phase and neutral conductors and
phase conductor and earth
ii Test the strength of the cable insulation
iii Test Equipment ndash Insulation Resistance Tester operating voltage is 250VDC or 500VDC
iv Test Method
1 1048766 Switch off main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
59 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
4 1048766 Carry out test as in the Table below
5 1048766 Meter reading value shall be less than 1 Megaohm
60 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
61 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Insulation resitance test
62 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
INSULATION RESISTANCE TEST BETWEEN CONDUCTORS AND OPPOSITE POLARITY
Polarity Testi Ensure that each fuse or single pole control and protection device is connected only in the phase
conductor
ii Intermediate contact of Edison screw lamp holder is connected to the phase conductor
iii Ensure that phase neutral and earth conductors at socket outlets are connected at the correct
terminals
iv Test Equipment ndash Multimeter (Ohm range) or Ohm meter
v Test Method
1 1048766 Switch off Main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in Figure 85
63 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
5 1048766 Test switches and single phase control devices at the phase conductors
6 1048766 Test socket outlet connection sources
7 1048766 Test Edison screw lamp holder connections
8 1048766 Meter reading value shall be less than 1 Ω
64 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Polarity test
65 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Earth Electrode Resistance Testi To test the earth electrode resistance
ii To ascertain the suitability of the location of the electrode
iii To ensure that the electrode is not buried within the resistance area of another electrode
iv Test equipment ndash Earth Resistance Tester
v Test method -
1 1048766 Terminal rsquoErsquo is connected to the electrode to be tested (green conductor)
2 1048766 Terminal lsquoPrsquo is connected to the potential spike (yellow conductor) at a distance of 10
meters from the earth electrode
3 1048766 Terminal lsquoCrsquo is connected to the current spike (red conductor) at a distance of 20 meters
from the earth electrode
Earth Electrode Resistance Measurement Method (Figure 86)
This test must be repeated at least three times to ensure that the reading is not affected by interacting
earthing regions
i Record the first reading (Z1) Example Z1 = 10 Ω
ii Move the voltage spike to a distance of 6 meters from the original position Record the second
reading (Z2 ) Example Z2 = 10 Ω
iii Move the voltage spike to a distance of 6 meters from the original position Record the third
reading (Z3) Example Z3 = 10 Ω
66 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Residual Current Device Testi Ensure that the residual current device (RCD) trips within the set time on the occurrence of current
leakage to earth
ii Test Equipment ndash RCD Tester RCCB Tester
iii Test Method 1
1 1048766 Use the Trip Test Button
2 1048766 Press the trip button found on the RCD to determine if it trips or otherwise This test would
not be able to determine the sensitivity of the RCD nor the time taken for it to trip
iv Test Method 2
i 1048766 Use a RCD Tester
ii This equipment is equipped with a 13A plug which can be connected to a 13A socket outlet
Select the RCD sensitivity to be the same as the sensitivity of the RCD to be tested to
determine if the RCD can trip The time to trip shall not exceed 40 mS
iii 1048766 Test method ndash
a) Position the selection switch in accordance with the sensitivity of the RCD used
Example 100 mA 01 A
b) Position the operations switch to lsquoNo Triprsquo (frac12 Rated mA = 50) connect the 3 pin plug to
the 13A socket outlet
67 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
c) Switch on the 13A socket outlet ndash ensure that the P-N and P-E lights light up
This shows that the polarity is correct (Note if both the lights as above do not light up the test cannot
be continued)
d) Press the test button ndash the reading shows less than 200 mS and simultaneously the lsquotestrsquo light lights
up and the P-N and P-E lights do not light up At that instant the RCD will not trip
e) Move the selection switch to 180o (+ve wave) ndash repeat steps (d) and (e) Move the operations
switch to lsquoTriprsquo (Rated mA = 100)
g) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200mS
h) Move the selection switch to 0o (-ve wave)
i) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
j) The above test is repeated until a near correct reading is obtained
k) Record the test results
l) Change the operations switch to lsquoFast Triprsquo and press the test button ndash RCD will trip within a
time not exceeding 40 millisecond
m) Repeat a number of times at 0o or 180o
On completion of a wiring installation a number of tests on the installation have to be conducted to
ascertain that the wiring circuits and connected appliances are safe for use Prior to carrying out the
tests an inspection has to be done the following tests shall be conducted
i Continuity Test
ii Insulation Resistance Test
iii Polarity Test
iv Earth Electrode Resistance test and
v Residual Current Device Test
821 Continuity Test
There are 3 main types of continuity tests for the final circuits-
i Protection Conductor Continuity Test
ii Final Ring Circuit Conductor Continuity Test
68 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
iii Live and Neutral Conductor Continuity Test
a) Protection Conductor Continuity Test
bull To ascertain that all protection conductors are connected in the correct and effective manner
bull Test equipment ndash Multimeter (Ohm range) or Ohm meter
bull Test Method
1 1048766 Ensure that the main switch RCD and MCB are open circuited (switched off) and all loads are
disconnected
2 1048766 Connected the test leads as in the Figure 81
3 1048766 The meter reading shall be less than 1 Ω
Final Ring Circuit Conductor Continuity Test
bull To ensure that all conductors around the ring circuit have continuity
bull Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
bull Test Method
1 1048766 Disconnect both the supply source live conductors from the MCB the neutral conductor
from the neutral terminals and the earth conductor from the earth terminal in the distribution
fuse box
2 1048766 Connect the test leads as in the Figure 82 (EE)
3 1048766 Repeat the procedure for (L-L) and (N-N)
4 1048766 The meter reading value shall be less than 1 ohm Figure 82 - Final Ring Circuit Conductor
Continuity Test Ohm Meter
Disconnect both the supply source cables from mcbfuse
Take readings at earth conductors of both sources and note resistance readings
Live and Neutral Conductor Continuity Test
1 To ensure that each conductor in the circuit has continuity
2 Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
3 Test Method
1 1048766 Switch off the Main switch RCD and MCB
2 1048766 Disconnect all loads
3 1048766 Switch on all switches in the circuit
4 1048766 Disconnect the fusesfinal circuit breakers and close the circuit
5 1048766 Carry out the test as shown in Figure 83
6 1048766 The meter reading value shall be less than 1 ohm Figure 83 - Live and Neutral
Conductor Continuity Test Ohm Meter
Insulation Resistance Test
69 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
i Ensure that there is no leakage current between phase conductors phase and neutral conductors and
phase conductor and earth
ii Test the strength of the cable insulation
iii Test Equipment ndash Insulation Resistance Tester Operating voltage is 250VDC or 500VDC
iv Test Method
1 1048766 Switch off main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in the Table below
5 1048766 Meter reading value shall be less than 1 Megaohm
Polarity Test
i Ensure that each fuse or single pole control and protection device is connected only in the phase
conductor
ii Intermediate contact of Edison screw lamp holder is connected to the phase conductor
iii Ensure that phase neutral and earth conductors at socket outlets are connected at the correct
terminals
iv Test Equipment ndash Multimeter (Ohm range) or Ohm meter
v Test Method
1 1048766 Switch off Main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in Figure 85
5 1048766 Test switches and single phase control devices at the phase conductors
6 1048766 Test socket outlet connection sources
7 1048766 Test Edison screw lamp holder connections
8 1048766 Meter reading value shall be less than 1 Ω
Earth Electrode Resistance Test
i To test the earth electrode resistance
70 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
ii To ascertain the suitability of the location of the electrode
iii To ensure that the electrode is not buried within the resistance area of another electrode
iv Test equipment ndash Earth Resistance Tester
v Test method -
1 1048766 Terminal rsquoErsquo is connected to the electrode to be tested (green conductor)
2 1048766 Terminal lsquoPrsquo is connected to the potential spike (yellow conductor) at a distance of 10
meters from the earth electrode
3 1048766 Terminal lsquoCrsquo is connected to the current spike (red conductor) at a distance of 20 meters
from the earth electrode E P C Electrode 10 meter 10 meter
Figure 86 ndash Earth Electrode Resistance Measurement Test Equipment
Earth Electrode Resistance Measurement Method (Figure 86)
This test must be repeated at least three times to ensure that the reading is not affected by interacting
earthing regions
i Record the first reading (Z1) Example Z1 = 10 Ω
ii Move the voltage spike to a distance of 6 meters from the original position Record the second
reading (Z2) Example Z2 = 10 Ω
iii Move the voltage spike to a distance of 6 meters from the original position Record the third
reading (Z3)
Example Z3 = 10 Ω
Residual Current Device Test
71 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
i Ensure that the residual current device (RCD) trips within the set time on the occurrence of current
leakage to earth
ii Test Equipment ndash RCD Tester RCCB Tester
iii Test Method 1
1 1048766 Use the Trip Test Button
2 1048766 Press the trip button found on the RCD to determine if it trips or otherwise This test would
not be able to determine the sensitivity of the RCD nor the time taken for it to trip
iv Test Method 2
1048766 Use a RCD Tester
This equipment is equipped with a 13A plug which can be connected to a 13A socket outlet Select the
RCD sensitivity to be the same as the sensitivity of the RCD to be tested to determine if the RCD can
trip The time to trip shall not exceed 40 mS
1048766 Test method ndash
a) Position the selection switch in accordance with the sensitivity of the RCD used
Example 100 mA 01 A
b) Position the operations switch to lsquoNo Triprsquo (frac12 Rated mA = 50) connect the 3 pin plug to
the 13A socket outlet
c) Switch on the 13A socket outlet ndash ensure that the P-N and P-E lights light up This shows that
the polarity is correct (Note if both the lights as above do not light up the test cannot be
continued)
d) Press the test button ndash the reading shows less than 200 millisecond and simultaneously the
lsquotestrsquo light lights up and the P-N and P-E lights do not light up At that instant the RCD will
not trip
e) Move the selection switch to 180o (+ve wave) ndash repeat steps (d) and (e) = 100)
f) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
g) Move the selection switch to 0o (-ve wave)
h) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
i) The above test is repeated until a near correct reading is obtained
j) Record the test results
k) Change the operations switch to lsquoFast Triprsquo and press the test button ndash RCD will trip within a
time not exceeding 40 mS
l) Repeat a number of times at 0o or 180o
72 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 9 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (DC)
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
73 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Start stop button 240Vac 5A 2
9 Filament lamp (Bulb ) 240Vac 40W 3
10 Overload Relay 415V 20A 3
11 Three phase induction motor 5 hp 3
12 Single phase step down transformer 2500VA 1
13 Single core PVC insulated Cable 1mm 2 As required
14 Single core PVC insulated Cable 25mm 2 As required
15 DIN rail 35 mm As required
16 PVC type Cable tray 50 mm x 50 mm As required
17 Cable ties 4 ldquo As required
18 Flexible wires 05 mm As required
19 PVC Connectors 5 A amp 20 A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the schematic
diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a optional exercise
i Simple DOL starter
ii Forward reverse DOL starter
iii Forward Reverse Dahlander motor
iv Three motors operated in sequence by DOL starter operated by manual push
button or time delay relay
74 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
a One loop per-cycle
b Continuous operation in a loop
c optional circuit design to represent the same task
v Only one out of three motors to be operated at a time (quiz)
4 Test the functionality of completed project
LESSON 10 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (AC)
75 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 1
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Lamp point 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
76 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
11 Overload Relay 415V 20A 3
12 Three phase induction
motor
5 hp 3
13 Single core PVC insulated
Cable
1mm 2 As required
14 Single core PVC insulated
Cable
25mm 2 As required
15 DIN rail 35 mm As required
16 PVC type Cable tray 50 mm x 50 mm As required
17 Cable ties 4 ldquo As required
18 Flexible wires 05 mm As required
19 PVC Connectors 5 A amp 20 A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the
schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram optional exercise
4 Simple DOL starter
5 Forward reverse DOL starter
6 Test the functionality of completed project
77 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 1
78 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
cm
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Indicating light 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
11 Overload Relay 415V 20A 3
12 Three phase induction motor 5 hp 3
13 Single phase step down
transformer
2500VA 1
14 Single core PVC insulated
Cable
1mm 2 As required
15 Single core PVC insulated
Cable
25mm 2 As required
16 DIN rail 35 mm As required
17 PVC type Cable tray 50 mm x 50 mm As required
18 Cable ties 4 ldquo As required
19 Flexible wires 05 mm As required
20 PVC Connectors 5 A amp 20 A 240 V As required
21 Single pole MCB 6A 240 V 1
22 Single pole MCB 2A 240 V 1
23 Triple pole MCB 20A 415 V 1
24 Mounting board 30 cm x 40 cm x 3
cm
1
25 Relay cw 11 pin socket 10 A 240 Vac 2
26 Time delay relay 10 A 240 Vac 3
27 Triple pole Contactor 20A 240Vac 3
28 Batten type Lamp holder 240Vac 10 A 3
29 Start stop button 240Vac 10A 2
30 Indicating light (Bulb ) 240Vac 25W 3
31 Overload Relay 415V 20A 1
32 Three phase dahlander type
induction motor
5 hp 1
33 Single phase step down
transformer
24024Vac
2500VA
1
79 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
34 Single core PVC insulated
Cable
1mm 2 As required
35 Single core PVC insulated
Cable
25mm 2 As required
36 DIN rail 35 mm As required
37 PVC type Cable tray 50 mm x 50 mm As required
38 Cable ties 4 ldquo As required
39 Flexible wires 075 mm As required
40 PVC Connectors 5 A amp 20 A 240 V As required
41 Terminal block 20A 240Vac As required
Procedures
5 Identify each component according to specification and quantity required from the schematic
diagram attached
6 Test the functionality of each component by using multi-meter or power supply whichever
applicable
7 Wire component according to circuit diagram
8 Three motors operated in sequence by DOL starter operated by manual push button or time
delay relay
a One loop per-cycle
b Continuous operation in a loop
c optional circuit design to represent the same task
d Only one out of three motors to be operated at a time (quiz)
9 Test the functionality of completed project
80 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
BASIC DESIGN INDUSTRIAL MOTOR CONTROL (SEQUENCE CONTROL)
THREE PHASE INDUCTION MOTOR OPERATED IN SEQUENCE BY DIRECT ON LINE
STARTER
LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
81 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
82 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Lcd lamp indicator 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
11 Overload Relay 415V 20A 3
12 Three phase induction motor 5 hp 3
13 Single phase step down transformer 2500VA 1
14 Single core PVC insulated Cable 1mm 2 As required
15 Single core PVC insulated Cable 25mm 2 As required
16 DIN rail 35 mm As required
17 PVC type Cable tray 50 mm x 50 mm As required
18 Cable ties 4 ldquo As required
19 Flexible wires 1 mm Oslash As required
20 PVC Terminal block 10A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the schematic
diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a optional exercise
i Forward Reverse dahlander motor
4 Test the functionality of completed project
83 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
THREE PHASE DAHLANDER TYPE INDUCTION MOTOR OPERATED FORWARD AND
REVERSE OPERATION BY DIRECT ON LINE STARTER
84 ndash 99EASYTECH ENTERPRISE
LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
Introduction
If a motors windings are connected in the star configuration any two phases will be in series across
the supply and hence the line current will be smaller(by 577) than if the windings were connected in
the delta arrangement
Hence larger-type motors with heavy starting currents are first connected in star and then when the
starting currents fall in delta This of course means that all six of the ends of the windings must be
brought to terminations outside the casing (Fig 833)
EZTECH
EZTECH ELECTRICAL INSTALLATION GUIDE
The automatic version of this starter incorporates a timing relay which automatically changes the
connections from star to delta Figs 834 and 835 show the wiring and schematic diagrams for a star
delta starter
Objectives
1 Identify component and the specification
2 Design forward reverse star delta starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
2 ndash 99EASYTECH ENTERPRISE
REV -C
LEGENDMCCB Moulded Case Circuit BreakerTOR Thermal Over Load RelayFOW-C Mains Forward ContactorREV-C Mains Reverse ContactorDC Delta ContactorSC Star ContactorS-SW Mains Selector Switch
SC
V2
W2
U2
DC
V1
W1
U1
TOR
TOR
FOW-C
30A MCCB
TOR
MAIN CIRCUIT FORWARD REVERSE STAR DELTA
RYBN S
-SW
3 PHASEINDUCTION MOTOR
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Relay 10 A 240V 3
5 Triple pole Contactor
6 cw NO NC auxiliary contact
240Vac 20 A 4
7 Overload Relay 415 V 1
8 LED indicator 240vac 5 A 4
9 Start stop button 240Vac 5A 2
10 DIN rail 35 mm As required
11 Flexible wires 1 mm As required
12 Single core PVC insulated
wire
25 mm As required
13 Terminal block 20 A As required
14 Squirrel cage motor 5kW 1
15 5 pin plug and socket 415V 20A 1
16 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
3 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
a Manual star delta
b Manual Forward reverse star delta starter
c Automatic star delta starter
d Automatic Forward reverse star delta starter
4 Test the functionality of completed project
4 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
Objectives
1 Identify component and the specification
2 Design auto transformer starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
5 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Autotransformer starter is used to start a 3 phase induction motor that has a rating between 10 to 15 hp
6 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Autotransformer set 10Kw 415 V 50 Hz 1
5 Triple pole Contactor 240Vac 4
6 Batten type Lamp holder 240 Vac 105 A 4
7 Start stop button 240Vac 10A 4
8 Filament lamp (Bulb ) 240Vac 40W 4
9 DIN rail 35 mm As required
10 Flexible wires 1 mm As required
7 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
11 Single core PVC insulated
wire
25 mm As required
12 Terminal block 20 A As required
13 Squirrel cage motor 10kW 1
14 5 pin plug and socket 415V 20A 1
15 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a open transient autotransformer starter
b close transient autotransformer starter
c Forward reverse autotransformer starter
4 Test the functionality of completed project
8 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
Objectives
1 Identify component and the specification
2 Design rotor resistance starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
9 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Rotor Resistor set 10kW 1
5 Triple pole Contactor 240Vac 20A 4
6 Indicating light 240vac 5 A 4
7 Start stop push button 240Vac 5A 4
8 DIN rail 35 mm As required
9 Flexible wires 1 mm 2 As required
10 Single core PVC insulated wire 25 mm 2 As required
11 Terminal block 20 A As required
12 Slip Ring motor 10kW 1
13 5 pin round 3 phase socket 415V 20A 1
14 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
10 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
4 Test the functionality of completed project
a Dead circuit test b Life circuit test
5 Measure starting and running Amps
LESSON 16
TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
An installation in general will suffer damage
Damage usually occurs on the electric motor control as follows
1 Damage to the main circuit
2 Damage to the control circuit
The cause of the damage
i Overcurrent overload short circuit
ii Leakage current to ground
iii Equipment malfunction
iv The main control circuit
a Trip of main circuit protection devices fire
b Defect of motor terminal such as short circuit fire loose
v The control circuit is not functioning -
a contactor relay relay time overload relay does not work damaged burned
b Loose cable connection disconnected
Detecting and Repairing Damage
Examples of damage are as follows
i Motor does not work
ii Motor function and overload relay trips
iii Motor function but only partially functional control circuit
Methods of detecting damage
Among the known methods necessary to detect damage are as follows
1 Turn off the electricity at the main switch (main switch) in order to avoid any danger during the
work carried out to detect damage
2 Check all the protective gear that controls the motor control main circuit
11 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
3 Make sure the damage function control circuit
4 Check the control circuit according to the schematic circuit diagram of the motor control
5 Check the operation of the control circuit
Note
Use wiring that has been installed on the SYSTEM OF MOTOR CONTROL BOARD by Forward
Reverse control circuit for Star Delta to test and look for damage
SELF-ASSESSMENT QUESTIONS
1 (a) Explain what is meant by the term lsquoback emfrsquo in a motor
(b) Outline the basic differences between series shunt and compound wound dc motors
2 (a) With the aid of diagrams explain how the speed of series shunt and compound-wound motors
may be controlled
(b) A 440V dc shunt-wound motor has a field resistance of 200R and an armature resistance of 06 R
When its speed is 20 rev d second the current drawn from the supply is 122A Calculate its back
emf at this speed If the speed were decreased to 19 revssecond the field flux remaining unchanged
calculate the new back emf and the new armature current
3 A load of 64 kW at 240 V is supplied from the terminals of a shunt-wound dc generator The field
resistance is 180 A Calculate the armature current
4 (a) Explain with the aid of a diagram how a rotating magnetic field may be
(b) What is meant by lsquosynchronous speedrsquo
Calculate the synchronous obtained speed of a 12 pole motor if the supply frequency is 50Hz
5 (a) Explain the action of a synchronous motor
(b) What methods are available to start a synchronous motor Explain with diagrams
6 (a) Explain the action of a cage induction motor
(b) What is meant by the term lsquosliprsquo
Calculate the percentage slip of a six pole induction motor running at 162 revssecond from a 50 Hz
supply
7 Describe with sketches three different ways of starting a single-phase induction motor
12 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
8 Explain with the aid of a sketch the action of a three-phase DOL starter
What are dashpots used for How are remote start and stop buttons connected
9 A I0 kW 240V 50Hz single-phase cage rotor induction motor is 85efficient and has a PF of 068
lagging Calculate the motor current and the value of capacitor required to raise the PF to 093
lagging
10 Calculate the torque developed by an 18 kW four-pole induction motor run at 35 slip from a
50Hz supply
APPENDIX 1
13 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 11
14 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 111
Attachment Reference
httpswwwtlc-directcoukBook621htm
httpwwwstgovmyindexphpms
15 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
58 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
CONTINUITY TEST
Insulation Resistance Test
i Ensure that there is no leakage current between phase conductors phase and neutral conductors and
phase conductor and earth
ii Test the strength of the cable insulation
iii Test Equipment ndash Insulation Resistance Tester operating voltage is 250VDC or 500VDC
iv Test Method
1 1048766 Switch off main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
59 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
4 1048766 Carry out test as in the Table below
5 1048766 Meter reading value shall be less than 1 Megaohm
60 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
61 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Insulation resitance test
62 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
INSULATION RESISTANCE TEST BETWEEN CONDUCTORS AND OPPOSITE POLARITY
Polarity Testi Ensure that each fuse or single pole control and protection device is connected only in the phase
conductor
ii Intermediate contact of Edison screw lamp holder is connected to the phase conductor
iii Ensure that phase neutral and earth conductors at socket outlets are connected at the correct
terminals
iv Test Equipment ndash Multimeter (Ohm range) or Ohm meter
v Test Method
1 1048766 Switch off Main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in Figure 85
63 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
5 1048766 Test switches and single phase control devices at the phase conductors
6 1048766 Test socket outlet connection sources
7 1048766 Test Edison screw lamp holder connections
8 1048766 Meter reading value shall be less than 1 Ω
64 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Polarity test
65 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Earth Electrode Resistance Testi To test the earth electrode resistance
ii To ascertain the suitability of the location of the electrode
iii To ensure that the electrode is not buried within the resistance area of another electrode
iv Test equipment ndash Earth Resistance Tester
v Test method -
1 1048766 Terminal rsquoErsquo is connected to the electrode to be tested (green conductor)
2 1048766 Terminal lsquoPrsquo is connected to the potential spike (yellow conductor) at a distance of 10
meters from the earth electrode
3 1048766 Terminal lsquoCrsquo is connected to the current spike (red conductor) at a distance of 20 meters
from the earth electrode
Earth Electrode Resistance Measurement Method (Figure 86)
This test must be repeated at least three times to ensure that the reading is not affected by interacting
earthing regions
i Record the first reading (Z1) Example Z1 = 10 Ω
ii Move the voltage spike to a distance of 6 meters from the original position Record the second
reading (Z2 ) Example Z2 = 10 Ω
iii Move the voltage spike to a distance of 6 meters from the original position Record the third
reading (Z3) Example Z3 = 10 Ω
66 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Residual Current Device Testi Ensure that the residual current device (RCD) trips within the set time on the occurrence of current
leakage to earth
ii Test Equipment ndash RCD Tester RCCB Tester
iii Test Method 1
1 1048766 Use the Trip Test Button
2 1048766 Press the trip button found on the RCD to determine if it trips or otherwise This test would
not be able to determine the sensitivity of the RCD nor the time taken for it to trip
iv Test Method 2
i 1048766 Use a RCD Tester
ii This equipment is equipped with a 13A plug which can be connected to a 13A socket outlet
Select the RCD sensitivity to be the same as the sensitivity of the RCD to be tested to
determine if the RCD can trip The time to trip shall not exceed 40 mS
iii 1048766 Test method ndash
a) Position the selection switch in accordance with the sensitivity of the RCD used
Example 100 mA 01 A
b) Position the operations switch to lsquoNo Triprsquo (frac12 Rated mA = 50) connect the 3 pin plug to
the 13A socket outlet
67 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
c) Switch on the 13A socket outlet ndash ensure that the P-N and P-E lights light up
This shows that the polarity is correct (Note if both the lights as above do not light up the test cannot
be continued)
d) Press the test button ndash the reading shows less than 200 mS and simultaneously the lsquotestrsquo light lights
up and the P-N and P-E lights do not light up At that instant the RCD will not trip
e) Move the selection switch to 180o (+ve wave) ndash repeat steps (d) and (e) Move the operations
switch to lsquoTriprsquo (Rated mA = 100)
g) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200mS
h) Move the selection switch to 0o (-ve wave)
i) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
j) The above test is repeated until a near correct reading is obtained
k) Record the test results
l) Change the operations switch to lsquoFast Triprsquo and press the test button ndash RCD will trip within a
time not exceeding 40 millisecond
m) Repeat a number of times at 0o or 180o
On completion of a wiring installation a number of tests on the installation have to be conducted to
ascertain that the wiring circuits and connected appliances are safe for use Prior to carrying out the
tests an inspection has to be done the following tests shall be conducted
i Continuity Test
ii Insulation Resistance Test
iii Polarity Test
iv Earth Electrode Resistance test and
v Residual Current Device Test
821 Continuity Test
There are 3 main types of continuity tests for the final circuits-
i Protection Conductor Continuity Test
ii Final Ring Circuit Conductor Continuity Test
68 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
iii Live and Neutral Conductor Continuity Test
a) Protection Conductor Continuity Test
bull To ascertain that all protection conductors are connected in the correct and effective manner
bull Test equipment ndash Multimeter (Ohm range) or Ohm meter
bull Test Method
1 1048766 Ensure that the main switch RCD and MCB are open circuited (switched off) and all loads are
disconnected
2 1048766 Connected the test leads as in the Figure 81
3 1048766 The meter reading shall be less than 1 Ω
Final Ring Circuit Conductor Continuity Test
bull To ensure that all conductors around the ring circuit have continuity
bull Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
bull Test Method
1 1048766 Disconnect both the supply source live conductors from the MCB the neutral conductor
from the neutral terminals and the earth conductor from the earth terminal in the distribution
fuse box
2 1048766 Connect the test leads as in the Figure 82 (EE)
3 1048766 Repeat the procedure for (L-L) and (N-N)
4 1048766 The meter reading value shall be less than 1 ohm Figure 82 - Final Ring Circuit Conductor
Continuity Test Ohm Meter
Disconnect both the supply source cables from mcbfuse
Take readings at earth conductors of both sources and note resistance readings
Live and Neutral Conductor Continuity Test
1 To ensure that each conductor in the circuit has continuity
2 Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
3 Test Method
1 1048766 Switch off the Main switch RCD and MCB
2 1048766 Disconnect all loads
3 1048766 Switch on all switches in the circuit
4 1048766 Disconnect the fusesfinal circuit breakers and close the circuit
5 1048766 Carry out the test as shown in Figure 83
6 1048766 The meter reading value shall be less than 1 ohm Figure 83 - Live and Neutral
Conductor Continuity Test Ohm Meter
Insulation Resistance Test
69 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
i Ensure that there is no leakage current between phase conductors phase and neutral conductors and
phase conductor and earth
ii Test the strength of the cable insulation
iii Test Equipment ndash Insulation Resistance Tester Operating voltage is 250VDC or 500VDC
iv Test Method
1 1048766 Switch off main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in the Table below
5 1048766 Meter reading value shall be less than 1 Megaohm
Polarity Test
i Ensure that each fuse or single pole control and protection device is connected only in the phase
conductor
ii Intermediate contact of Edison screw lamp holder is connected to the phase conductor
iii Ensure that phase neutral and earth conductors at socket outlets are connected at the correct
terminals
iv Test Equipment ndash Multimeter (Ohm range) or Ohm meter
v Test Method
1 1048766 Switch off Main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in Figure 85
5 1048766 Test switches and single phase control devices at the phase conductors
6 1048766 Test socket outlet connection sources
7 1048766 Test Edison screw lamp holder connections
8 1048766 Meter reading value shall be less than 1 Ω
Earth Electrode Resistance Test
i To test the earth electrode resistance
70 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
ii To ascertain the suitability of the location of the electrode
iii To ensure that the electrode is not buried within the resistance area of another electrode
iv Test equipment ndash Earth Resistance Tester
v Test method -
1 1048766 Terminal rsquoErsquo is connected to the electrode to be tested (green conductor)
2 1048766 Terminal lsquoPrsquo is connected to the potential spike (yellow conductor) at a distance of 10
meters from the earth electrode
3 1048766 Terminal lsquoCrsquo is connected to the current spike (red conductor) at a distance of 20 meters
from the earth electrode E P C Electrode 10 meter 10 meter
Figure 86 ndash Earth Electrode Resistance Measurement Test Equipment
Earth Electrode Resistance Measurement Method (Figure 86)
This test must be repeated at least three times to ensure that the reading is not affected by interacting
earthing regions
i Record the first reading (Z1) Example Z1 = 10 Ω
ii Move the voltage spike to a distance of 6 meters from the original position Record the second
reading (Z2) Example Z2 = 10 Ω
iii Move the voltage spike to a distance of 6 meters from the original position Record the third
reading (Z3)
Example Z3 = 10 Ω
Residual Current Device Test
71 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
i Ensure that the residual current device (RCD) trips within the set time on the occurrence of current
leakage to earth
ii Test Equipment ndash RCD Tester RCCB Tester
iii Test Method 1
1 1048766 Use the Trip Test Button
2 1048766 Press the trip button found on the RCD to determine if it trips or otherwise This test would
not be able to determine the sensitivity of the RCD nor the time taken for it to trip
iv Test Method 2
1048766 Use a RCD Tester
This equipment is equipped with a 13A plug which can be connected to a 13A socket outlet Select the
RCD sensitivity to be the same as the sensitivity of the RCD to be tested to determine if the RCD can
trip The time to trip shall not exceed 40 mS
1048766 Test method ndash
a) Position the selection switch in accordance with the sensitivity of the RCD used
Example 100 mA 01 A
b) Position the operations switch to lsquoNo Triprsquo (frac12 Rated mA = 50) connect the 3 pin plug to
the 13A socket outlet
c) Switch on the 13A socket outlet ndash ensure that the P-N and P-E lights light up This shows that
the polarity is correct (Note if both the lights as above do not light up the test cannot be
continued)
d) Press the test button ndash the reading shows less than 200 millisecond and simultaneously the
lsquotestrsquo light lights up and the P-N and P-E lights do not light up At that instant the RCD will
not trip
e) Move the selection switch to 180o (+ve wave) ndash repeat steps (d) and (e) = 100)
f) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
g) Move the selection switch to 0o (-ve wave)
h) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
i) The above test is repeated until a near correct reading is obtained
j) Record the test results
k) Change the operations switch to lsquoFast Triprsquo and press the test button ndash RCD will trip within a
time not exceeding 40 mS
l) Repeat a number of times at 0o or 180o
72 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 9 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (DC)
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
73 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Start stop button 240Vac 5A 2
9 Filament lamp (Bulb ) 240Vac 40W 3
10 Overload Relay 415V 20A 3
11 Three phase induction motor 5 hp 3
12 Single phase step down transformer 2500VA 1
13 Single core PVC insulated Cable 1mm 2 As required
14 Single core PVC insulated Cable 25mm 2 As required
15 DIN rail 35 mm As required
16 PVC type Cable tray 50 mm x 50 mm As required
17 Cable ties 4 ldquo As required
18 Flexible wires 05 mm As required
19 PVC Connectors 5 A amp 20 A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the schematic
diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a optional exercise
i Simple DOL starter
ii Forward reverse DOL starter
iii Forward Reverse Dahlander motor
iv Three motors operated in sequence by DOL starter operated by manual push
button or time delay relay
74 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
a One loop per-cycle
b Continuous operation in a loop
c optional circuit design to represent the same task
v Only one out of three motors to be operated at a time (quiz)
4 Test the functionality of completed project
LESSON 10 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (AC)
75 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 1
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Lamp point 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
76 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
11 Overload Relay 415V 20A 3
12 Three phase induction
motor
5 hp 3
13 Single core PVC insulated
Cable
1mm 2 As required
14 Single core PVC insulated
Cable
25mm 2 As required
15 DIN rail 35 mm As required
16 PVC type Cable tray 50 mm x 50 mm As required
17 Cable ties 4 ldquo As required
18 Flexible wires 05 mm As required
19 PVC Connectors 5 A amp 20 A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the
schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram optional exercise
4 Simple DOL starter
5 Forward reverse DOL starter
6 Test the functionality of completed project
77 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 1
78 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
cm
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Indicating light 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
11 Overload Relay 415V 20A 3
12 Three phase induction motor 5 hp 3
13 Single phase step down
transformer
2500VA 1
14 Single core PVC insulated
Cable
1mm 2 As required
15 Single core PVC insulated
Cable
25mm 2 As required
16 DIN rail 35 mm As required
17 PVC type Cable tray 50 mm x 50 mm As required
18 Cable ties 4 ldquo As required
19 Flexible wires 05 mm As required
20 PVC Connectors 5 A amp 20 A 240 V As required
21 Single pole MCB 6A 240 V 1
22 Single pole MCB 2A 240 V 1
23 Triple pole MCB 20A 415 V 1
24 Mounting board 30 cm x 40 cm x 3
cm
1
25 Relay cw 11 pin socket 10 A 240 Vac 2
26 Time delay relay 10 A 240 Vac 3
27 Triple pole Contactor 20A 240Vac 3
28 Batten type Lamp holder 240Vac 10 A 3
29 Start stop button 240Vac 10A 2
30 Indicating light (Bulb ) 240Vac 25W 3
31 Overload Relay 415V 20A 1
32 Three phase dahlander type
induction motor
5 hp 1
33 Single phase step down
transformer
24024Vac
2500VA
1
79 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
34 Single core PVC insulated
Cable
1mm 2 As required
35 Single core PVC insulated
Cable
25mm 2 As required
36 DIN rail 35 mm As required
37 PVC type Cable tray 50 mm x 50 mm As required
38 Cable ties 4 ldquo As required
39 Flexible wires 075 mm As required
40 PVC Connectors 5 A amp 20 A 240 V As required
41 Terminal block 20A 240Vac As required
Procedures
5 Identify each component according to specification and quantity required from the schematic
diagram attached
6 Test the functionality of each component by using multi-meter or power supply whichever
applicable
7 Wire component according to circuit diagram
8 Three motors operated in sequence by DOL starter operated by manual push button or time
delay relay
a One loop per-cycle
b Continuous operation in a loop
c optional circuit design to represent the same task
d Only one out of three motors to be operated at a time (quiz)
9 Test the functionality of completed project
80 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
BASIC DESIGN INDUSTRIAL MOTOR CONTROL (SEQUENCE CONTROL)
THREE PHASE INDUCTION MOTOR OPERATED IN SEQUENCE BY DIRECT ON LINE
STARTER
LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
81 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
82 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Lcd lamp indicator 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
11 Overload Relay 415V 20A 3
12 Three phase induction motor 5 hp 3
13 Single phase step down transformer 2500VA 1
14 Single core PVC insulated Cable 1mm 2 As required
15 Single core PVC insulated Cable 25mm 2 As required
16 DIN rail 35 mm As required
17 PVC type Cable tray 50 mm x 50 mm As required
18 Cable ties 4 ldquo As required
19 Flexible wires 1 mm Oslash As required
20 PVC Terminal block 10A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the schematic
diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a optional exercise
i Forward Reverse dahlander motor
4 Test the functionality of completed project
83 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
THREE PHASE DAHLANDER TYPE INDUCTION MOTOR OPERATED FORWARD AND
REVERSE OPERATION BY DIRECT ON LINE STARTER
84 ndash 99EASYTECH ENTERPRISE
LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
Introduction
If a motors windings are connected in the star configuration any two phases will be in series across
the supply and hence the line current will be smaller(by 577) than if the windings were connected in
the delta arrangement
Hence larger-type motors with heavy starting currents are first connected in star and then when the
starting currents fall in delta This of course means that all six of the ends of the windings must be
brought to terminations outside the casing (Fig 833)
EZTECH
EZTECH ELECTRICAL INSTALLATION GUIDE
The automatic version of this starter incorporates a timing relay which automatically changes the
connections from star to delta Figs 834 and 835 show the wiring and schematic diagrams for a star
delta starter
Objectives
1 Identify component and the specification
2 Design forward reverse star delta starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
2 ndash 99EASYTECH ENTERPRISE
REV -C
LEGENDMCCB Moulded Case Circuit BreakerTOR Thermal Over Load RelayFOW-C Mains Forward ContactorREV-C Mains Reverse ContactorDC Delta ContactorSC Star ContactorS-SW Mains Selector Switch
SC
V2
W2
U2
DC
V1
W1
U1
TOR
TOR
FOW-C
30A MCCB
TOR
MAIN CIRCUIT FORWARD REVERSE STAR DELTA
RYBN S
-SW
3 PHASEINDUCTION MOTOR
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Relay 10 A 240V 3
5 Triple pole Contactor
6 cw NO NC auxiliary contact
240Vac 20 A 4
7 Overload Relay 415 V 1
8 LED indicator 240vac 5 A 4
9 Start stop button 240Vac 5A 2
10 DIN rail 35 mm As required
11 Flexible wires 1 mm As required
12 Single core PVC insulated
wire
25 mm As required
13 Terminal block 20 A As required
14 Squirrel cage motor 5kW 1
15 5 pin plug and socket 415V 20A 1
16 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
3 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
a Manual star delta
b Manual Forward reverse star delta starter
c Automatic star delta starter
d Automatic Forward reverse star delta starter
4 Test the functionality of completed project
4 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
Objectives
1 Identify component and the specification
2 Design auto transformer starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
5 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Autotransformer starter is used to start a 3 phase induction motor that has a rating between 10 to 15 hp
6 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Autotransformer set 10Kw 415 V 50 Hz 1
5 Triple pole Contactor 240Vac 4
6 Batten type Lamp holder 240 Vac 105 A 4
7 Start stop button 240Vac 10A 4
8 Filament lamp (Bulb ) 240Vac 40W 4
9 DIN rail 35 mm As required
10 Flexible wires 1 mm As required
7 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
11 Single core PVC insulated
wire
25 mm As required
12 Terminal block 20 A As required
13 Squirrel cage motor 10kW 1
14 5 pin plug and socket 415V 20A 1
15 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a open transient autotransformer starter
b close transient autotransformer starter
c Forward reverse autotransformer starter
4 Test the functionality of completed project
8 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
Objectives
1 Identify component and the specification
2 Design rotor resistance starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
9 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Rotor Resistor set 10kW 1
5 Triple pole Contactor 240Vac 20A 4
6 Indicating light 240vac 5 A 4
7 Start stop push button 240Vac 5A 4
8 DIN rail 35 mm As required
9 Flexible wires 1 mm 2 As required
10 Single core PVC insulated wire 25 mm 2 As required
11 Terminal block 20 A As required
12 Slip Ring motor 10kW 1
13 5 pin round 3 phase socket 415V 20A 1
14 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
10 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
4 Test the functionality of completed project
a Dead circuit test b Life circuit test
5 Measure starting and running Amps
LESSON 16
TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
An installation in general will suffer damage
Damage usually occurs on the electric motor control as follows
1 Damage to the main circuit
2 Damage to the control circuit
The cause of the damage
i Overcurrent overload short circuit
ii Leakage current to ground
iii Equipment malfunction
iv The main control circuit
a Trip of main circuit protection devices fire
b Defect of motor terminal such as short circuit fire loose
v The control circuit is not functioning -
a contactor relay relay time overload relay does not work damaged burned
b Loose cable connection disconnected
Detecting and Repairing Damage
Examples of damage are as follows
i Motor does not work
ii Motor function and overload relay trips
iii Motor function but only partially functional control circuit
Methods of detecting damage
Among the known methods necessary to detect damage are as follows
1 Turn off the electricity at the main switch (main switch) in order to avoid any danger during the
work carried out to detect damage
2 Check all the protective gear that controls the motor control main circuit
11 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
3 Make sure the damage function control circuit
4 Check the control circuit according to the schematic circuit diagram of the motor control
5 Check the operation of the control circuit
Note
Use wiring that has been installed on the SYSTEM OF MOTOR CONTROL BOARD by Forward
Reverse control circuit for Star Delta to test and look for damage
SELF-ASSESSMENT QUESTIONS
1 (a) Explain what is meant by the term lsquoback emfrsquo in a motor
(b) Outline the basic differences between series shunt and compound wound dc motors
2 (a) With the aid of diagrams explain how the speed of series shunt and compound-wound motors
may be controlled
(b) A 440V dc shunt-wound motor has a field resistance of 200R and an armature resistance of 06 R
When its speed is 20 rev d second the current drawn from the supply is 122A Calculate its back
emf at this speed If the speed were decreased to 19 revssecond the field flux remaining unchanged
calculate the new back emf and the new armature current
3 A load of 64 kW at 240 V is supplied from the terminals of a shunt-wound dc generator The field
resistance is 180 A Calculate the armature current
4 (a) Explain with the aid of a diagram how a rotating magnetic field may be
(b) What is meant by lsquosynchronous speedrsquo
Calculate the synchronous obtained speed of a 12 pole motor if the supply frequency is 50Hz
5 (a) Explain the action of a synchronous motor
(b) What methods are available to start a synchronous motor Explain with diagrams
6 (a) Explain the action of a cage induction motor
(b) What is meant by the term lsquosliprsquo
Calculate the percentage slip of a six pole induction motor running at 162 revssecond from a 50 Hz
supply
7 Describe with sketches three different ways of starting a single-phase induction motor
12 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
8 Explain with the aid of a sketch the action of a three-phase DOL starter
What are dashpots used for How are remote start and stop buttons connected
9 A I0 kW 240V 50Hz single-phase cage rotor induction motor is 85efficient and has a PF of 068
lagging Calculate the motor current and the value of capacitor required to raise the PF to 093
lagging
10 Calculate the torque developed by an 18 kW four-pole induction motor run at 35 slip from a
50Hz supply
APPENDIX 1
13 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 11
14 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 111
Attachment Reference
httpswwwtlc-directcoukBook621htm
httpwwwstgovmyindexphpms
15 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
CONTINUITY TEST
Insulation Resistance Test
i Ensure that there is no leakage current between phase conductors phase and neutral conductors and
phase conductor and earth
ii Test the strength of the cable insulation
iii Test Equipment ndash Insulation Resistance Tester operating voltage is 250VDC or 500VDC
iv Test Method
1 1048766 Switch off main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
59 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
4 1048766 Carry out test as in the Table below
5 1048766 Meter reading value shall be less than 1 Megaohm
60 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
61 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Insulation resitance test
62 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
INSULATION RESISTANCE TEST BETWEEN CONDUCTORS AND OPPOSITE POLARITY
Polarity Testi Ensure that each fuse or single pole control and protection device is connected only in the phase
conductor
ii Intermediate contact of Edison screw lamp holder is connected to the phase conductor
iii Ensure that phase neutral and earth conductors at socket outlets are connected at the correct
terminals
iv Test Equipment ndash Multimeter (Ohm range) or Ohm meter
v Test Method
1 1048766 Switch off Main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in Figure 85
63 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
5 1048766 Test switches and single phase control devices at the phase conductors
6 1048766 Test socket outlet connection sources
7 1048766 Test Edison screw lamp holder connections
8 1048766 Meter reading value shall be less than 1 Ω
64 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Polarity test
65 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Earth Electrode Resistance Testi To test the earth electrode resistance
ii To ascertain the suitability of the location of the electrode
iii To ensure that the electrode is not buried within the resistance area of another electrode
iv Test equipment ndash Earth Resistance Tester
v Test method -
1 1048766 Terminal rsquoErsquo is connected to the electrode to be tested (green conductor)
2 1048766 Terminal lsquoPrsquo is connected to the potential spike (yellow conductor) at a distance of 10
meters from the earth electrode
3 1048766 Terminal lsquoCrsquo is connected to the current spike (red conductor) at a distance of 20 meters
from the earth electrode
Earth Electrode Resistance Measurement Method (Figure 86)
This test must be repeated at least three times to ensure that the reading is not affected by interacting
earthing regions
i Record the first reading (Z1) Example Z1 = 10 Ω
ii Move the voltage spike to a distance of 6 meters from the original position Record the second
reading (Z2 ) Example Z2 = 10 Ω
iii Move the voltage spike to a distance of 6 meters from the original position Record the third
reading (Z3) Example Z3 = 10 Ω
66 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Residual Current Device Testi Ensure that the residual current device (RCD) trips within the set time on the occurrence of current
leakage to earth
ii Test Equipment ndash RCD Tester RCCB Tester
iii Test Method 1
1 1048766 Use the Trip Test Button
2 1048766 Press the trip button found on the RCD to determine if it trips or otherwise This test would
not be able to determine the sensitivity of the RCD nor the time taken for it to trip
iv Test Method 2
i 1048766 Use a RCD Tester
ii This equipment is equipped with a 13A plug which can be connected to a 13A socket outlet
Select the RCD sensitivity to be the same as the sensitivity of the RCD to be tested to
determine if the RCD can trip The time to trip shall not exceed 40 mS
iii 1048766 Test method ndash
a) Position the selection switch in accordance with the sensitivity of the RCD used
Example 100 mA 01 A
b) Position the operations switch to lsquoNo Triprsquo (frac12 Rated mA = 50) connect the 3 pin plug to
the 13A socket outlet
67 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
c) Switch on the 13A socket outlet ndash ensure that the P-N and P-E lights light up
This shows that the polarity is correct (Note if both the lights as above do not light up the test cannot
be continued)
d) Press the test button ndash the reading shows less than 200 mS and simultaneously the lsquotestrsquo light lights
up and the P-N and P-E lights do not light up At that instant the RCD will not trip
e) Move the selection switch to 180o (+ve wave) ndash repeat steps (d) and (e) Move the operations
switch to lsquoTriprsquo (Rated mA = 100)
g) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200mS
h) Move the selection switch to 0o (-ve wave)
i) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
j) The above test is repeated until a near correct reading is obtained
k) Record the test results
l) Change the operations switch to lsquoFast Triprsquo and press the test button ndash RCD will trip within a
time not exceeding 40 millisecond
m) Repeat a number of times at 0o or 180o
On completion of a wiring installation a number of tests on the installation have to be conducted to
ascertain that the wiring circuits and connected appliances are safe for use Prior to carrying out the
tests an inspection has to be done the following tests shall be conducted
i Continuity Test
ii Insulation Resistance Test
iii Polarity Test
iv Earth Electrode Resistance test and
v Residual Current Device Test
821 Continuity Test
There are 3 main types of continuity tests for the final circuits-
i Protection Conductor Continuity Test
ii Final Ring Circuit Conductor Continuity Test
68 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
iii Live and Neutral Conductor Continuity Test
a) Protection Conductor Continuity Test
bull To ascertain that all protection conductors are connected in the correct and effective manner
bull Test equipment ndash Multimeter (Ohm range) or Ohm meter
bull Test Method
1 1048766 Ensure that the main switch RCD and MCB are open circuited (switched off) and all loads are
disconnected
2 1048766 Connected the test leads as in the Figure 81
3 1048766 The meter reading shall be less than 1 Ω
Final Ring Circuit Conductor Continuity Test
bull To ensure that all conductors around the ring circuit have continuity
bull Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
bull Test Method
1 1048766 Disconnect both the supply source live conductors from the MCB the neutral conductor
from the neutral terminals and the earth conductor from the earth terminal in the distribution
fuse box
2 1048766 Connect the test leads as in the Figure 82 (EE)
3 1048766 Repeat the procedure for (L-L) and (N-N)
4 1048766 The meter reading value shall be less than 1 ohm Figure 82 - Final Ring Circuit Conductor
Continuity Test Ohm Meter
Disconnect both the supply source cables from mcbfuse
Take readings at earth conductors of both sources and note resistance readings
Live and Neutral Conductor Continuity Test
1 To ensure that each conductor in the circuit has continuity
2 Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
3 Test Method
1 1048766 Switch off the Main switch RCD and MCB
2 1048766 Disconnect all loads
3 1048766 Switch on all switches in the circuit
4 1048766 Disconnect the fusesfinal circuit breakers and close the circuit
5 1048766 Carry out the test as shown in Figure 83
6 1048766 The meter reading value shall be less than 1 ohm Figure 83 - Live and Neutral
Conductor Continuity Test Ohm Meter
Insulation Resistance Test
69 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
i Ensure that there is no leakage current between phase conductors phase and neutral conductors and
phase conductor and earth
ii Test the strength of the cable insulation
iii Test Equipment ndash Insulation Resistance Tester Operating voltage is 250VDC or 500VDC
iv Test Method
1 1048766 Switch off main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in the Table below
5 1048766 Meter reading value shall be less than 1 Megaohm
Polarity Test
i Ensure that each fuse or single pole control and protection device is connected only in the phase
conductor
ii Intermediate contact of Edison screw lamp holder is connected to the phase conductor
iii Ensure that phase neutral and earth conductors at socket outlets are connected at the correct
terminals
iv Test Equipment ndash Multimeter (Ohm range) or Ohm meter
v Test Method
1 1048766 Switch off Main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in Figure 85
5 1048766 Test switches and single phase control devices at the phase conductors
6 1048766 Test socket outlet connection sources
7 1048766 Test Edison screw lamp holder connections
8 1048766 Meter reading value shall be less than 1 Ω
Earth Electrode Resistance Test
i To test the earth electrode resistance
70 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
ii To ascertain the suitability of the location of the electrode
iii To ensure that the electrode is not buried within the resistance area of another electrode
iv Test equipment ndash Earth Resistance Tester
v Test method -
1 1048766 Terminal rsquoErsquo is connected to the electrode to be tested (green conductor)
2 1048766 Terminal lsquoPrsquo is connected to the potential spike (yellow conductor) at a distance of 10
meters from the earth electrode
3 1048766 Terminal lsquoCrsquo is connected to the current spike (red conductor) at a distance of 20 meters
from the earth electrode E P C Electrode 10 meter 10 meter
Figure 86 ndash Earth Electrode Resistance Measurement Test Equipment
Earth Electrode Resistance Measurement Method (Figure 86)
This test must be repeated at least three times to ensure that the reading is not affected by interacting
earthing regions
i Record the first reading (Z1) Example Z1 = 10 Ω
ii Move the voltage spike to a distance of 6 meters from the original position Record the second
reading (Z2) Example Z2 = 10 Ω
iii Move the voltage spike to a distance of 6 meters from the original position Record the third
reading (Z3)
Example Z3 = 10 Ω
Residual Current Device Test
71 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
i Ensure that the residual current device (RCD) trips within the set time on the occurrence of current
leakage to earth
ii Test Equipment ndash RCD Tester RCCB Tester
iii Test Method 1
1 1048766 Use the Trip Test Button
2 1048766 Press the trip button found on the RCD to determine if it trips or otherwise This test would
not be able to determine the sensitivity of the RCD nor the time taken for it to trip
iv Test Method 2
1048766 Use a RCD Tester
This equipment is equipped with a 13A plug which can be connected to a 13A socket outlet Select the
RCD sensitivity to be the same as the sensitivity of the RCD to be tested to determine if the RCD can
trip The time to trip shall not exceed 40 mS
1048766 Test method ndash
a) Position the selection switch in accordance with the sensitivity of the RCD used
Example 100 mA 01 A
b) Position the operations switch to lsquoNo Triprsquo (frac12 Rated mA = 50) connect the 3 pin plug to
the 13A socket outlet
c) Switch on the 13A socket outlet ndash ensure that the P-N and P-E lights light up This shows that
the polarity is correct (Note if both the lights as above do not light up the test cannot be
continued)
d) Press the test button ndash the reading shows less than 200 millisecond and simultaneously the
lsquotestrsquo light lights up and the P-N and P-E lights do not light up At that instant the RCD will
not trip
e) Move the selection switch to 180o (+ve wave) ndash repeat steps (d) and (e) = 100)
f) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
g) Move the selection switch to 0o (-ve wave)
h) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
i) The above test is repeated until a near correct reading is obtained
j) Record the test results
k) Change the operations switch to lsquoFast Triprsquo and press the test button ndash RCD will trip within a
time not exceeding 40 mS
l) Repeat a number of times at 0o or 180o
72 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 9 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (DC)
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
73 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Start stop button 240Vac 5A 2
9 Filament lamp (Bulb ) 240Vac 40W 3
10 Overload Relay 415V 20A 3
11 Three phase induction motor 5 hp 3
12 Single phase step down transformer 2500VA 1
13 Single core PVC insulated Cable 1mm 2 As required
14 Single core PVC insulated Cable 25mm 2 As required
15 DIN rail 35 mm As required
16 PVC type Cable tray 50 mm x 50 mm As required
17 Cable ties 4 ldquo As required
18 Flexible wires 05 mm As required
19 PVC Connectors 5 A amp 20 A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the schematic
diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a optional exercise
i Simple DOL starter
ii Forward reverse DOL starter
iii Forward Reverse Dahlander motor
iv Three motors operated in sequence by DOL starter operated by manual push
button or time delay relay
74 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
a One loop per-cycle
b Continuous operation in a loop
c optional circuit design to represent the same task
v Only one out of three motors to be operated at a time (quiz)
4 Test the functionality of completed project
LESSON 10 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (AC)
75 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 1
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Lamp point 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
76 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
11 Overload Relay 415V 20A 3
12 Three phase induction
motor
5 hp 3
13 Single core PVC insulated
Cable
1mm 2 As required
14 Single core PVC insulated
Cable
25mm 2 As required
15 DIN rail 35 mm As required
16 PVC type Cable tray 50 mm x 50 mm As required
17 Cable ties 4 ldquo As required
18 Flexible wires 05 mm As required
19 PVC Connectors 5 A amp 20 A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the
schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram optional exercise
4 Simple DOL starter
5 Forward reverse DOL starter
6 Test the functionality of completed project
77 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 1
78 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
cm
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Indicating light 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
11 Overload Relay 415V 20A 3
12 Three phase induction motor 5 hp 3
13 Single phase step down
transformer
2500VA 1
14 Single core PVC insulated
Cable
1mm 2 As required
15 Single core PVC insulated
Cable
25mm 2 As required
16 DIN rail 35 mm As required
17 PVC type Cable tray 50 mm x 50 mm As required
18 Cable ties 4 ldquo As required
19 Flexible wires 05 mm As required
20 PVC Connectors 5 A amp 20 A 240 V As required
21 Single pole MCB 6A 240 V 1
22 Single pole MCB 2A 240 V 1
23 Triple pole MCB 20A 415 V 1
24 Mounting board 30 cm x 40 cm x 3
cm
1
25 Relay cw 11 pin socket 10 A 240 Vac 2
26 Time delay relay 10 A 240 Vac 3
27 Triple pole Contactor 20A 240Vac 3
28 Batten type Lamp holder 240Vac 10 A 3
29 Start stop button 240Vac 10A 2
30 Indicating light (Bulb ) 240Vac 25W 3
31 Overload Relay 415V 20A 1
32 Three phase dahlander type
induction motor
5 hp 1
33 Single phase step down
transformer
24024Vac
2500VA
1
79 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
34 Single core PVC insulated
Cable
1mm 2 As required
35 Single core PVC insulated
Cable
25mm 2 As required
36 DIN rail 35 mm As required
37 PVC type Cable tray 50 mm x 50 mm As required
38 Cable ties 4 ldquo As required
39 Flexible wires 075 mm As required
40 PVC Connectors 5 A amp 20 A 240 V As required
41 Terminal block 20A 240Vac As required
Procedures
5 Identify each component according to specification and quantity required from the schematic
diagram attached
6 Test the functionality of each component by using multi-meter or power supply whichever
applicable
7 Wire component according to circuit diagram
8 Three motors operated in sequence by DOL starter operated by manual push button or time
delay relay
a One loop per-cycle
b Continuous operation in a loop
c optional circuit design to represent the same task
d Only one out of three motors to be operated at a time (quiz)
9 Test the functionality of completed project
80 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
BASIC DESIGN INDUSTRIAL MOTOR CONTROL (SEQUENCE CONTROL)
THREE PHASE INDUCTION MOTOR OPERATED IN SEQUENCE BY DIRECT ON LINE
STARTER
LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
81 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
82 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Lcd lamp indicator 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
11 Overload Relay 415V 20A 3
12 Three phase induction motor 5 hp 3
13 Single phase step down transformer 2500VA 1
14 Single core PVC insulated Cable 1mm 2 As required
15 Single core PVC insulated Cable 25mm 2 As required
16 DIN rail 35 mm As required
17 PVC type Cable tray 50 mm x 50 mm As required
18 Cable ties 4 ldquo As required
19 Flexible wires 1 mm Oslash As required
20 PVC Terminal block 10A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the schematic
diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a optional exercise
i Forward Reverse dahlander motor
4 Test the functionality of completed project
83 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
THREE PHASE DAHLANDER TYPE INDUCTION MOTOR OPERATED FORWARD AND
REVERSE OPERATION BY DIRECT ON LINE STARTER
84 ndash 99EASYTECH ENTERPRISE
LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
Introduction
If a motors windings are connected in the star configuration any two phases will be in series across
the supply and hence the line current will be smaller(by 577) than if the windings were connected in
the delta arrangement
Hence larger-type motors with heavy starting currents are first connected in star and then when the
starting currents fall in delta This of course means that all six of the ends of the windings must be
brought to terminations outside the casing (Fig 833)
EZTECH
EZTECH ELECTRICAL INSTALLATION GUIDE
The automatic version of this starter incorporates a timing relay which automatically changes the
connections from star to delta Figs 834 and 835 show the wiring and schematic diagrams for a star
delta starter
Objectives
1 Identify component and the specification
2 Design forward reverse star delta starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
2 ndash 99EASYTECH ENTERPRISE
REV -C
LEGENDMCCB Moulded Case Circuit BreakerTOR Thermal Over Load RelayFOW-C Mains Forward ContactorREV-C Mains Reverse ContactorDC Delta ContactorSC Star ContactorS-SW Mains Selector Switch
SC
V2
W2
U2
DC
V1
W1
U1
TOR
TOR
FOW-C
30A MCCB
TOR
MAIN CIRCUIT FORWARD REVERSE STAR DELTA
RYBN S
-SW
3 PHASEINDUCTION MOTOR
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Relay 10 A 240V 3
5 Triple pole Contactor
6 cw NO NC auxiliary contact
240Vac 20 A 4
7 Overload Relay 415 V 1
8 LED indicator 240vac 5 A 4
9 Start stop button 240Vac 5A 2
10 DIN rail 35 mm As required
11 Flexible wires 1 mm As required
12 Single core PVC insulated
wire
25 mm As required
13 Terminal block 20 A As required
14 Squirrel cage motor 5kW 1
15 5 pin plug and socket 415V 20A 1
16 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
3 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
a Manual star delta
b Manual Forward reverse star delta starter
c Automatic star delta starter
d Automatic Forward reverse star delta starter
4 Test the functionality of completed project
4 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
Objectives
1 Identify component and the specification
2 Design auto transformer starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
5 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Autotransformer starter is used to start a 3 phase induction motor that has a rating between 10 to 15 hp
6 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Autotransformer set 10Kw 415 V 50 Hz 1
5 Triple pole Contactor 240Vac 4
6 Batten type Lamp holder 240 Vac 105 A 4
7 Start stop button 240Vac 10A 4
8 Filament lamp (Bulb ) 240Vac 40W 4
9 DIN rail 35 mm As required
10 Flexible wires 1 mm As required
7 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
11 Single core PVC insulated
wire
25 mm As required
12 Terminal block 20 A As required
13 Squirrel cage motor 10kW 1
14 5 pin plug and socket 415V 20A 1
15 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a open transient autotransformer starter
b close transient autotransformer starter
c Forward reverse autotransformer starter
4 Test the functionality of completed project
8 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
Objectives
1 Identify component and the specification
2 Design rotor resistance starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
9 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Rotor Resistor set 10kW 1
5 Triple pole Contactor 240Vac 20A 4
6 Indicating light 240vac 5 A 4
7 Start stop push button 240Vac 5A 4
8 DIN rail 35 mm As required
9 Flexible wires 1 mm 2 As required
10 Single core PVC insulated wire 25 mm 2 As required
11 Terminal block 20 A As required
12 Slip Ring motor 10kW 1
13 5 pin round 3 phase socket 415V 20A 1
14 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
10 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
4 Test the functionality of completed project
a Dead circuit test b Life circuit test
5 Measure starting and running Amps
LESSON 16
TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
An installation in general will suffer damage
Damage usually occurs on the electric motor control as follows
1 Damage to the main circuit
2 Damage to the control circuit
The cause of the damage
i Overcurrent overload short circuit
ii Leakage current to ground
iii Equipment malfunction
iv The main control circuit
a Trip of main circuit protection devices fire
b Defect of motor terminal such as short circuit fire loose
v The control circuit is not functioning -
a contactor relay relay time overload relay does not work damaged burned
b Loose cable connection disconnected
Detecting and Repairing Damage
Examples of damage are as follows
i Motor does not work
ii Motor function and overload relay trips
iii Motor function but only partially functional control circuit
Methods of detecting damage
Among the known methods necessary to detect damage are as follows
1 Turn off the electricity at the main switch (main switch) in order to avoid any danger during the
work carried out to detect damage
2 Check all the protective gear that controls the motor control main circuit
11 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
3 Make sure the damage function control circuit
4 Check the control circuit according to the schematic circuit diagram of the motor control
5 Check the operation of the control circuit
Note
Use wiring that has been installed on the SYSTEM OF MOTOR CONTROL BOARD by Forward
Reverse control circuit for Star Delta to test and look for damage
SELF-ASSESSMENT QUESTIONS
1 (a) Explain what is meant by the term lsquoback emfrsquo in a motor
(b) Outline the basic differences between series shunt and compound wound dc motors
2 (a) With the aid of diagrams explain how the speed of series shunt and compound-wound motors
may be controlled
(b) A 440V dc shunt-wound motor has a field resistance of 200R and an armature resistance of 06 R
When its speed is 20 rev d second the current drawn from the supply is 122A Calculate its back
emf at this speed If the speed were decreased to 19 revssecond the field flux remaining unchanged
calculate the new back emf and the new armature current
3 A load of 64 kW at 240 V is supplied from the terminals of a shunt-wound dc generator The field
resistance is 180 A Calculate the armature current
4 (a) Explain with the aid of a diagram how a rotating magnetic field may be
(b) What is meant by lsquosynchronous speedrsquo
Calculate the synchronous obtained speed of a 12 pole motor if the supply frequency is 50Hz
5 (a) Explain the action of a synchronous motor
(b) What methods are available to start a synchronous motor Explain with diagrams
6 (a) Explain the action of a cage induction motor
(b) What is meant by the term lsquosliprsquo
Calculate the percentage slip of a six pole induction motor running at 162 revssecond from a 50 Hz
supply
7 Describe with sketches three different ways of starting a single-phase induction motor
12 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
8 Explain with the aid of a sketch the action of a three-phase DOL starter
What are dashpots used for How are remote start and stop buttons connected
9 A I0 kW 240V 50Hz single-phase cage rotor induction motor is 85efficient and has a PF of 068
lagging Calculate the motor current and the value of capacitor required to raise the PF to 093
lagging
10 Calculate the torque developed by an 18 kW four-pole induction motor run at 35 slip from a
50Hz supply
APPENDIX 1
13 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 11
14 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 111
Attachment Reference
httpswwwtlc-directcoukBook621htm
httpwwwstgovmyindexphpms
15 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
4 1048766 Carry out test as in the Table below
5 1048766 Meter reading value shall be less than 1 Megaohm
60 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
61 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Insulation resitance test
62 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
INSULATION RESISTANCE TEST BETWEEN CONDUCTORS AND OPPOSITE POLARITY
Polarity Testi Ensure that each fuse or single pole control and protection device is connected only in the phase
conductor
ii Intermediate contact of Edison screw lamp holder is connected to the phase conductor
iii Ensure that phase neutral and earth conductors at socket outlets are connected at the correct
terminals
iv Test Equipment ndash Multimeter (Ohm range) or Ohm meter
v Test Method
1 1048766 Switch off Main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in Figure 85
63 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
5 1048766 Test switches and single phase control devices at the phase conductors
6 1048766 Test socket outlet connection sources
7 1048766 Test Edison screw lamp holder connections
8 1048766 Meter reading value shall be less than 1 Ω
64 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Polarity test
65 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Earth Electrode Resistance Testi To test the earth electrode resistance
ii To ascertain the suitability of the location of the electrode
iii To ensure that the electrode is not buried within the resistance area of another electrode
iv Test equipment ndash Earth Resistance Tester
v Test method -
1 1048766 Terminal rsquoErsquo is connected to the electrode to be tested (green conductor)
2 1048766 Terminal lsquoPrsquo is connected to the potential spike (yellow conductor) at a distance of 10
meters from the earth electrode
3 1048766 Terminal lsquoCrsquo is connected to the current spike (red conductor) at a distance of 20 meters
from the earth electrode
Earth Electrode Resistance Measurement Method (Figure 86)
This test must be repeated at least three times to ensure that the reading is not affected by interacting
earthing regions
i Record the first reading (Z1) Example Z1 = 10 Ω
ii Move the voltage spike to a distance of 6 meters from the original position Record the second
reading (Z2 ) Example Z2 = 10 Ω
iii Move the voltage spike to a distance of 6 meters from the original position Record the third
reading (Z3) Example Z3 = 10 Ω
66 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Residual Current Device Testi Ensure that the residual current device (RCD) trips within the set time on the occurrence of current
leakage to earth
ii Test Equipment ndash RCD Tester RCCB Tester
iii Test Method 1
1 1048766 Use the Trip Test Button
2 1048766 Press the trip button found on the RCD to determine if it trips or otherwise This test would
not be able to determine the sensitivity of the RCD nor the time taken for it to trip
iv Test Method 2
i 1048766 Use a RCD Tester
ii This equipment is equipped with a 13A plug which can be connected to a 13A socket outlet
Select the RCD sensitivity to be the same as the sensitivity of the RCD to be tested to
determine if the RCD can trip The time to trip shall not exceed 40 mS
iii 1048766 Test method ndash
a) Position the selection switch in accordance with the sensitivity of the RCD used
Example 100 mA 01 A
b) Position the operations switch to lsquoNo Triprsquo (frac12 Rated mA = 50) connect the 3 pin plug to
the 13A socket outlet
67 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
c) Switch on the 13A socket outlet ndash ensure that the P-N and P-E lights light up
This shows that the polarity is correct (Note if both the lights as above do not light up the test cannot
be continued)
d) Press the test button ndash the reading shows less than 200 mS and simultaneously the lsquotestrsquo light lights
up and the P-N and P-E lights do not light up At that instant the RCD will not trip
e) Move the selection switch to 180o (+ve wave) ndash repeat steps (d) and (e) Move the operations
switch to lsquoTriprsquo (Rated mA = 100)
g) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200mS
h) Move the selection switch to 0o (-ve wave)
i) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
j) The above test is repeated until a near correct reading is obtained
k) Record the test results
l) Change the operations switch to lsquoFast Triprsquo and press the test button ndash RCD will trip within a
time not exceeding 40 millisecond
m) Repeat a number of times at 0o or 180o
On completion of a wiring installation a number of tests on the installation have to be conducted to
ascertain that the wiring circuits and connected appliances are safe for use Prior to carrying out the
tests an inspection has to be done the following tests shall be conducted
i Continuity Test
ii Insulation Resistance Test
iii Polarity Test
iv Earth Electrode Resistance test and
v Residual Current Device Test
821 Continuity Test
There are 3 main types of continuity tests for the final circuits-
i Protection Conductor Continuity Test
ii Final Ring Circuit Conductor Continuity Test
68 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
iii Live and Neutral Conductor Continuity Test
a) Protection Conductor Continuity Test
bull To ascertain that all protection conductors are connected in the correct and effective manner
bull Test equipment ndash Multimeter (Ohm range) or Ohm meter
bull Test Method
1 1048766 Ensure that the main switch RCD and MCB are open circuited (switched off) and all loads are
disconnected
2 1048766 Connected the test leads as in the Figure 81
3 1048766 The meter reading shall be less than 1 Ω
Final Ring Circuit Conductor Continuity Test
bull To ensure that all conductors around the ring circuit have continuity
bull Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
bull Test Method
1 1048766 Disconnect both the supply source live conductors from the MCB the neutral conductor
from the neutral terminals and the earth conductor from the earth terminal in the distribution
fuse box
2 1048766 Connect the test leads as in the Figure 82 (EE)
3 1048766 Repeat the procedure for (L-L) and (N-N)
4 1048766 The meter reading value shall be less than 1 ohm Figure 82 - Final Ring Circuit Conductor
Continuity Test Ohm Meter
Disconnect both the supply source cables from mcbfuse
Take readings at earth conductors of both sources and note resistance readings
Live and Neutral Conductor Continuity Test
1 To ensure that each conductor in the circuit has continuity
2 Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
3 Test Method
1 1048766 Switch off the Main switch RCD and MCB
2 1048766 Disconnect all loads
3 1048766 Switch on all switches in the circuit
4 1048766 Disconnect the fusesfinal circuit breakers and close the circuit
5 1048766 Carry out the test as shown in Figure 83
6 1048766 The meter reading value shall be less than 1 ohm Figure 83 - Live and Neutral
Conductor Continuity Test Ohm Meter
Insulation Resistance Test
69 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
i Ensure that there is no leakage current between phase conductors phase and neutral conductors and
phase conductor and earth
ii Test the strength of the cable insulation
iii Test Equipment ndash Insulation Resistance Tester Operating voltage is 250VDC or 500VDC
iv Test Method
1 1048766 Switch off main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in the Table below
5 1048766 Meter reading value shall be less than 1 Megaohm
Polarity Test
i Ensure that each fuse or single pole control and protection device is connected only in the phase
conductor
ii Intermediate contact of Edison screw lamp holder is connected to the phase conductor
iii Ensure that phase neutral and earth conductors at socket outlets are connected at the correct
terminals
iv Test Equipment ndash Multimeter (Ohm range) or Ohm meter
v Test Method
1 1048766 Switch off Main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in Figure 85
5 1048766 Test switches and single phase control devices at the phase conductors
6 1048766 Test socket outlet connection sources
7 1048766 Test Edison screw lamp holder connections
8 1048766 Meter reading value shall be less than 1 Ω
Earth Electrode Resistance Test
i To test the earth electrode resistance
70 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
ii To ascertain the suitability of the location of the electrode
iii To ensure that the electrode is not buried within the resistance area of another electrode
iv Test equipment ndash Earth Resistance Tester
v Test method -
1 1048766 Terminal rsquoErsquo is connected to the electrode to be tested (green conductor)
2 1048766 Terminal lsquoPrsquo is connected to the potential spike (yellow conductor) at a distance of 10
meters from the earth electrode
3 1048766 Terminal lsquoCrsquo is connected to the current spike (red conductor) at a distance of 20 meters
from the earth electrode E P C Electrode 10 meter 10 meter
Figure 86 ndash Earth Electrode Resistance Measurement Test Equipment
Earth Electrode Resistance Measurement Method (Figure 86)
This test must be repeated at least three times to ensure that the reading is not affected by interacting
earthing regions
i Record the first reading (Z1) Example Z1 = 10 Ω
ii Move the voltage spike to a distance of 6 meters from the original position Record the second
reading (Z2) Example Z2 = 10 Ω
iii Move the voltage spike to a distance of 6 meters from the original position Record the third
reading (Z3)
Example Z3 = 10 Ω
Residual Current Device Test
71 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
i Ensure that the residual current device (RCD) trips within the set time on the occurrence of current
leakage to earth
ii Test Equipment ndash RCD Tester RCCB Tester
iii Test Method 1
1 1048766 Use the Trip Test Button
2 1048766 Press the trip button found on the RCD to determine if it trips or otherwise This test would
not be able to determine the sensitivity of the RCD nor the time taken for it to trip
iv Test Method 2
1048766 Use a RCD Tester
This equipment is equipped with a 13A plug which can be connected to a 13A socket outlet Select the
RCD sensitivity to be the same as the sensitivity of the RCD to be tested to determine if the RCD can
trip The time to trip shall not exceed 40 mS
1048766 Test method ndash
a) Position the selection switch in accordance with the sensitivity of the RCD used
Example 100 mA 01 A
b) Position the operations switch to lsquoNo Triprsquo (frac12 Rated mA = 50) connect the 3 pin plug to
the 13A socket outlet
c) Switch on the 13A socket outlet ndash ensure that the P-N and P-E lights light up This shows that
the polarity is correct (Note if both the lights as above do not light up the test cannot be
continued)
d) Press the test button ndash the reading shows less than 200 millisecond and simultaneously the
lsquotestrsquo light lights up and the P-N and P-E lights do not light up At that instant the RCD will
not trip
e) Move the selection switch to 180o (+ve wave) ndash repeat steps (d) and (e) = 100)
f) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
g) Move the selection switch to 0o (-ve wave)
h) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
i) The above test is repeated until a near correct reading is obtained
j) Record the test results
k) Change the operations switch to lsquoFast Triprsquo and press the test button ndash RCD will trip within a
time not exceeding 40 mS
l) Repeat a number of times at 0o or 180o
72 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 9 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (DC)
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
73 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Start stop button 240Vac 5A 2
9 Filament lamp (Bulb ) 240Vac 40W 3
10 Overload Relay 415V 20A 3
11 Three phase induction motor 5 hp 3
12 Single phase step down transformer 2500VA 1
13 Single core PVC insulated Cable 1mm 2 As required
14 Single core PVC insulated Cable 25mm 2 As required
15 DIN rail 35 mm As required
16 PVC type Cable tray 50 mm x 50 mm As required
17 Cable ties 4 ldquo As required
18 Flexible wires 05 mm As required
19 PVC Connectors 5 A amp 20 A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the schematic
diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a optional exercise
i Simple DOL starter
ii Forward reverse DOL starter
iii Forward Reverse Dahlander motor
iv Three motors operated in sequence by DOL starter operated by manual push
button or time delay relay
74 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
a One loop per-cycle
b Continuous operation in a loop
c optional circuit design to represent the same task
v Only one out of three motors to be operated at a time (quiz)
4 Test the functionality of completed project
LESSON 10 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (AC)
75 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 1
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Lamp point 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
76 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
11 Overload Relay 415V 20A 3
12 Three phase induction
motor
5 hp 3
13 Single core PVC insulated
Cable
1mm 2 As required
14 Single core PVC insulated
Cable
25mm 2 As required
15 DIN rail 35 mm As required
16 PVC type Cable tray 50 mm x 50 mm As required
17 Cable ties 4 ldquo As required
18 Flexible wires 05 mm As required
19 PVC Connectors 5 A amp 20 A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the
schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram optional exercise
4 Simple DOL starter
5 Forward reverse DOL starter
6 Test the functionality of completed project
77 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 1
78 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
cm
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Indicating light 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
11 Overload Relay 415V 20A 3
12 Three phase induction motor 5 hp 3
13 Single phase step down
transformer
2500VA 1
14 Single core PVC insulated
Cable
1mm 2 As required
15 Single core PVC insulated
Cable
25mm 2 As required
16 DIN rail 35 mm As required
17 PVC type Cable tray 50 mm x 50 mm As required
18 Cable ties 4 ldquo As required
19 Flexible wires 05 mm As required
20 PVC Connectors 5 A amp 20 A 240 V As required
21 Single pole MCB 6A 240 V 1
22 Single pole MCB 2A 240 V 1
23 Triple pole MCB 20A 415 V 1
24 Mounting board 30 cm x 40 cm x 3
cm
1
25 Relay cw 11 pin socket 10 A 240 Vac 2
26 Time delay relay 10 A 240 Vac 3
27 Triple pole Contactor 20A 240Vac 3
28 Batten type Lamp holder 240Vac 10 A 3
29 Start stop button 240Vac 10A 2
30 Indicating light (Bulb ) 240Vac 25W 3
31 Overload Relay 415V 20A 1
32 Three phase dahlander type
induction motor
5 hp 1
33 Single phase step down
transformer
24024Vac
2500VA
1
79 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
34 Single core PVC insulated
Cable
1mm 2 As required
35 Single core PVC insulated
Cable
25mm 2 As required
36 DIN rail 35 mm As required
37 PVC type Cable tray 50 mm x 50 mm As required
38 Cable ties 4 ldquo As required
39 Flexible wires 075 mm As required
40 PVC Connectors 5 A amp 20 A 240 V As required
41 Terminal block 20A 240Vac As required
Procedures
5 Identify each component according to specification and quantity required from the schematic
diagram attached
6 Test the functionality of each component by using multi-meter or power supply whichever
applicable
7 Wire component according to circuit diagram
8 Three motors operated in sequence by DOL starter operated by manual push button or time
delay relay
a One loop per-cycle
b Continuous operation in a loop
c optional circuit design to represent the same task
d Only one out of three motors to be operated at a time (quiz)
9 Test the functionality of completed project
80 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
BASIC DESIGN INDUSTRIAL MOTOR CONTROL (SEQUENCE CONTROL)
THREE PHASE INDUCTION MOTOR OPERATED IN SEQUENCE BY DIRECT ON LINE
STARTER
LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
81 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
82 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Lcd lamp indicator 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
11 Overload Relay 415V 20A 3
12 Three phase induction motor 5 hp 3
13 Single phase step down transformer 2500VA 1
14 Single core PVC insulated Cable 1mm 2 As required
15 Single core PVC insulated Cable 25mm 2 As required
16 DIN rail 35 mm As required
17 PVC type Cable tray 50 mm x 50 mm As required
18 Cable ties 4 ldquo As required
19 Flexible wires 1 mm Oslash As required
20 PVC Terminal block 10A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the schematic
diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a optional exercise
i Forward Reverse dahlander motor
4 Test the functionality of completed project
83 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
THREE PHASE DAHLANDER TYPE INDUCTION MOTOR OPERATED FORWARD AND
REVERSE OPERATION BY DIRECT ON LINE STARTER
84 ndash 99EASYTECH ENTERPRISE
LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
Introduction
If a motors windings are connected in the star configuration any two phases will be in series across
the supply and hence the line current will be smaller(by 577) than if the windings were connected in
the delta arrangement
Hence larger-type motors with heavy starting currents are first connected in star and then when the
starting currents fall in delta This of course means that all six of the ends of the windings must be
brought to terminations outside the casing (Fig 833)
EZTECH
EZTECH ELECTRICAL INSTALLATION GUIDE
The automatic version of this starter incorporates a timing relay which automatically changes the
connections from star to delta Figs 834 and 835 show the wiring and schematic diagrams for a star
delta starter
Objectives
1 Identify component and the specification
2 Design forward reverse star delta starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
2 ndash 99EASYTECH ENTERPRISE
REV -C
LEGENDMCCB Moulded Case Circuit BreakerTOR Thermal Over Load RelayFOW-C Mains Forward ContactorREV-C Mains Reverse ContactorDC Delta ContactorSC Star ContactorS-SW Mains Selector Switch
SC
V2
W2
U2
DC
V1
W1
U1
TOR
TOR
FOW-C
30A MCCB
TOR
MAIN CIRCUIT FORWARD REVERSE STAR DELTA
RYBN S
-SW
3 PHASEINDUCTION MOTOR
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Relay 10 A 240V 3
5 Triple pole Contactor
6 cw NO NC auxiliary contact
240Vac 20 A 4
7 Overload Relay 415 V 1
8 LED indicator 240vac 5 A 4
9 Start stop button 240Vac 5A 2
10 DIN rail 35 mm As required
11 Flexible wires 1 mm As required
12 Single core PVC insulated
wire
25 mm As required
13 Terminal block 20 A As required
14 Squirrel cage motor 5kW 1
15 5 pin plug and socket 415V 20A 1
16 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
3 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
a Manual star delta
b Manual Forward reverse star delta starter
c Automatic star delta starter
d Automatic Forward reverse star delta starter
4 Test the functionality of completed project
4 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
Objectives
1 Identify component and the specification
2 Design auto transformer starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
5 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Autotransformer starter is used to start a 3 phase induction motor that has a rating between 10 to 15 hp
6 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Autotransformer set 10Kw 415 V 50 Hz 1
5 Triple pole Contactor 240Vac 4
6 Batten type Lamp holder 240 Vac 105 A 4
7 Start stop button 240Vac 10A 4
8 Filament lamp (Bulb ) 240Vac 40W 4
9 DIN rail 35 mm As required
10 Flexible wires 1 mm As required
7 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
11 Single core PVC insulated
wire
25 mm As required
12 Terminal block 20 A As required
13 Squirrel cage motor 10kW 1
14 5 pin plug and socket 415V 20A 1
15 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a open transient autotransformer starter
b close transient autotransformer starter
c Forward reverse autotransformer starter
4 Test the functionality of completed project
8 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
Objectives
1 Identify component and the specification
2 Design rotor resistance starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
9 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Rotor Resistor set 10kW 1
5 Triple pole Contactor 240Vac 20A 4
6 Indicating light 240vac 5 A 4
7 Start stop push button 240Vac 5A 4
8 DIN rail 35 mm As required
9 Flexible wires 1 mm 2 As required
10 Single core PVC insulated wire 25 mm 2 As required
11 Terminal block 20 A As required
12 Slip Ring motor 10kW 1
13 5 pin round 3 phase socket 415V 20A 1
14 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
10 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
4 Test the functionality of completed project
a Dead circuit test b Life circuit test
5 Measure starting and running Amps
LESSON 16
TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
An installation in general will suffer damage
Damage usually occurs on the electric motor control as follows
1 Damage to the main circuit
2 Damage to the control circuit
The cause of the damage
i Overcurrent overload short circuit
ii Leakage current to ground
iii Equipment malfunction
iv The main control circuit
a Trip of main circuit protection devices fire
b Defect of motor terminal such as short circuit fire loose
v The control circuit is not functioning -
a contactor relay relay time overload relay does not work damaged burned
b Loose cable connection disconnected
Detecting and Repairing Damage
Examples of damage are as follows
i Motor does not work
ii Motor function and overload relay trips
iii Motor function but only partially functional control circuit
Methods of detecting damage
Among the known methods necessary to detect damage are as follows
1 Turn off the electricity at the main switch (main switch) in order to avoid any danger during the
work carried out to detect damage
2 Check all the protective gear that controls the motor control main circuit
11 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
3 Make sure the damage function control circuit
4 Check the control circuit according to the schematic circuit diagram of the motor control
5 Check the operation of the control circuit
Note
Use wiring that has been installed on the SYSTEM OF MOTOR CONTROL BOARD by Forward
Reverse control circuit for Star Delta to test and look for damage
SELF-ASSESSMENT QUESTIONS
1 (a) Explain what is meant by the term lsquoback emfrsquo in a motor
(b) Outline the basic differences between series shunt and compound wound dc motors
2 (a) With the aid of diagrams explain how the speed of series shunt and compound-wound motors
may be controlled
(b) A 440V dc shunt-wound motor has a field resistance of 200R and an armature resistance of 06 R
When its speed is 20 rev d second the current drawn from the supply is 122A Calculate its back
emf at this speed If the speed were decreased to 19 revssecond the field flux remaining unchanged
calculate the new back emf and the new armature current
3 A load of 64 kW at 240 V is supplied from the terminals of a shunt-wound dc generator The field
resistance is 180 A Calculate the armature current
4 (a) Explain with the aid of a diagram how a rotating magnetic field may be
(b) What is meant by lsquosynchronous speedrsquo
Calculate the synchronous obtained speed of a 12 pole motor if the supply frequency is 50Hz
5 (a) Explain the action of a synchronous motor
(b) What methods are available to start a synchronous motor Explain with diagrams
6 (a) Explain the action of a cage induction motor
(b) What is meant by the term lsquosliprsquo
Calculate the percentage slip of a six pole induction motor running at 162 revssecond from a 50 Hz
supply
7 Describe with sketches three different ways of starting a single-phase induction motor
12 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
8 Explain with the aid of a sketch the action of a three-phase DOL starter
What are dashpots used for How are remote start and stop buttons connected
9 A I0 kW 240V 50Hz single-phase cage rotor induction motor is 85efficient and has a PF of 068
lagging Calculate the motor current and the value of capacitor required to raise the PF to 093
lagging
10 Calculate the torque developed by an 18 kW four-pole induction motor run at 35 slip from a
50Hz supply
APPENDIX 1
13 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 11
14 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 111
Attachment Reference
httpswwwtlc-directcoukBook621htm
httpwwwstgovmyindexphpms
15 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
61 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Insulation resitance test
62 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
INSULATION RESISTANCE TEST BETWEEN CONDUCTORS AND OPPOSITE POLARITY
Polarity Testi Ensure that each fuse or single pole control and protection device is connected only in the phase
conductor
ii Intermediate contact of Edison screw lamp holder is connected to the phase conductor
iii Ensure that phase neutral and earth conductors at socket outlets are connected at the correct
terminals
iv Test Equipment ndash Multimeter (Ohm range) or Ohm meter
v Test Method
1 1048766 Switch off Main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in Figure 85
63 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
5 1048766 Test switches and single phase control devices at the phase conductors
6 1048766 Test socket outlet connection sources
7 1048766 Test Edison screw lamp holder connections
8 1048766 Meter reading value shall be less than 1 Ω
64 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Polarity test
65 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Earth Electrode Resistance Testi To test the earth electrode resistance
ii To ascertain the suitability of the location of the electrode
iii To ensure that the electrode is not buried within the resistance area of another electrode
iv Test equipment ndash Earth Resistance Tester
v Test method -
1 1048766 Terminal rsquoErsquo is connected to the electrode to be tested (green conductor)
2 1048766 Terminal lsquoPrsquo is connected to the potential spike (yellow conductor) at a distance of 10
meters from the earth electrode
3 1048766 Terminal lsquoCrsquo is connected to the current spike (red conductor) at a distance of 20 meters
from the earth electrode
Earth Electrode Resistance Measurement Method (Figure 86)
This test must be repeated at least three times to ensure that the reading is not affected by interacting
earthing regions
i Record the first reading (Z1) Example Z1 = 10 Ω
ii Move the voltage spike to a distance of 6 meters from the original position Record the second
reading (Z2 ) Example Z2 = 10 Ω
iii Move the voltage spike to a distance of 6 meters from the original position Record the third
reading (Z3) Example Z3 = 10 Ω
66 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Residual Current Device Testi Ensure that the residual current device (RCD) trips within the set time on the occurrence of current
leakage to earth
ii Test Equipment ndash RCD Tester RCCB Tester
iii Test Method 1
1 1048766 Use the Trip Test Button
2 1048766 Press the trip button found on the RCD to determine if it trips or otherwise This test would
not be able to determine the sensitivity of the RCD nor the time taken for it to trip
iv Test Method 2
i 1048766 Use a RCD Tester
ii This equipment is equipped with a 13A plug which can be connected to a 13A socket outlet
Select the RCD sensitivity to be the same as the sensitivity of the RCD to be tested to
determine if the RCD can trip The time to trip shall not exceed 40 mS
iii 1048766 Test method ndash
a) Position the selection switch in accordance with the sensitivity of the RCD used
Example 100 mA 01 A
b) Position the operations switch to lsquoNo Triprsquo (frac12 Rated mA = 50) connect the 3 pin plug to
the 13A socket outlet
67 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
c) Switch on the 13A socket outlet ndash ensure that the P-N and P-E lights light up
This shows that the polarity is correct (Note if both the lights as above do not light up the test cannot
be continued)
d) Press the test button ndash the reading shows less than 200 mS and simultaneously the lsquotestrsquo light lights
up and the P-N and P-E lights do not light up At that instant the RCD will not trip
e) Move the selection switch to 180o (+ve wave) ndash repeat steps (d) and (e) Move the operations
switch to lsquoTriprsquo (Rated mA = 100)
g) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200mS
h) Move the selection switch to 0o (-ve wave)
i) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
j) The above test is repeated until a near correct reading is obtained
k) Record the test results
l) Change the operations switch to lsquoFast Triprsquo and press the test button ndash RCD will trip within a
time not exceeding 40 millisecond
m) Repeat a number of times at 0o or 180o
On completion of a wiring installation a number of tests on the installation have to be conducted to
ascertain that the wiring circuits and connected appliances are safe for use Prior to carrying out the
tests an inspection has to be done the following tests shall be conducted
i Continuity Test
ii Insulation Resistance Test
iii Polarity Test
iv Earth Electrode Resistance test and
v Residual Current Device Test
821 Continuity Test
There are 3 main types of continuity tests for the final circuits-
i Protection Conductor Continuity Test
ii Final Ring Circuit Conductor Continuity Test
68 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
iii Live and Neutral Conductor Continuity Test
a) Protection Conductor Continuity Test
bull To ascertain that all protection conductors are connected in the correct and effective manner
bull Test equipment ndash Multimeter (Ohm range) or Ohm meter
bull Test Method
1 1048766 Ensure that the main switch RCD and MCB are open circuited (switched off) and all loads are
disconnected
2 1048766 Connected the test leads as in the Figure 81
3 1048766 The meter reading shall be less than 1 Ω
Final Ring Circuit Conductor Continuity Test
bull To ensure that all conductors around the ring circuit have continuity
bull Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
bull Test Method
1 1048766 Disconnect both the supply source live conductors from the MCB the neutral conductor
from the neutral terminals and the earth conductor from the earth terminal in the distribution
fuse box
2 1048766 Connect the test leads as in the Figure 82 (EE)
3 1048766 Repeat the procedure for (L-L) and (N-N)
4 1048766 The meter reading value shall be less than 1 ohm Figure 82 - Final Ring Circuit Conductor
Continuity Test Ohm Meter
Disconnect both the supply source cables from mcbfuse
Take readings at earth conductors of both sources and note resistance readings
Live and Neutral Conductor Continuity Test
1 To ensure that each conductor in the circuit has continuity
2 Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
3 Test Method
1 1048766 Switch off the Main switch RCD and MCB
2 1048766 Disconnect all loads
3 1048766 Switch on all switches in the circuit
4 1048766 Disconnect the fusesfinal circuit breakers and close the circuit
5 1048766 Carry out the test as shown in Figure 83
6 1048766 The meter reading value shall be less than 1 ohm Figure 83 - Live and Neutral
Conductor Continuity Test Ohm Meter
Insulation Resistance Test
69 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
i Ensure that there is no leakage current between phase conductors phase and neutral conductors and
phase conductor and earth
ii Test the strength of the cable insulation
iii Test Equipment ndash Insulation Resistance Tester Operating voltage is 250VDC or 500VDC
iv Test Method
1 1048766 Switch off main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in the Table below
5 1048766 Meter reading value shall be less than 1 Megaohm
Polarity Test
i Ensure that each fuse or single pole control and protection device is connected only in the phase
conductor
ii Intermediate contact of Edison screw lamp holder is connected to the phase conductor
iii Ensure that phase neutral and earth conductors at socket outlets are connected at the correct
terminals
iv Test Equipment ndash Multimeter (Ohm range) or Ohm meter
v Test Method
1 1048766 Switch off Main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in Figure 85
5 1048766 Test switches and single phase control devices at the phase conductors
6 1048766 Test socket outlet connection sources
7 1048766 Test Edison screw lamp holder connections
8 1048766 Meter reading value shall be less than 1 Ω
Earth Electrode Resistance Test
i To test the earth electrode resistance
70 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
ii To ascertain the suitability of the location of the electrode
iii To ensure that the electrode is not buried within the resistance area of another electrode
iv Test equipment ndash Earth Resistance Tester
v Test method -
1 1048766 Terminal rsquoErsquo is connected to the electrode to be tested (green conductor)
2 1048766 Terminal lsquoPrsquo is connected to the potential spike (yellow conductor) at a distance of 10
meters from the earth electrode
3 1048766 Terminal lsquoCrsquo is connected to the current spike (red conductor) at a distance of 20 meters
from the earth electrode E P C Electrode 10 meter 10 meter
Figure 86 ndash Earth Electrode Resistance Measurement Test Equipment
Earth Electrode Resistance Measurement Method (Figure 86)
This test must be repeated at least three times to ensure that the reading is not affected by interacting
earthing regions
i Record the first reading (Z1) Example Z1 = 10 Ω
ii Move the voltage spike to a distance of 6 meters from the original position Record the second
reading (Z2) Example Z2 = 10 Ω
iii Move the voltage spike to a distance of 6 meters from the original position Record the third
reading (Z3)
Example Z3 = 10 Ω
Residual Current Device Test
71 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
i Ensure that the residual current device (RCD) trips within the set time on the occurrence of current
leakage to earth
ii Test Equipment ndash RCD Tester RCCB Tester
iii Test Method 1
1 1048766 Use the Trip Test Button
2 1048766 Press the trip button found on the RCD to determine if it trips or otherwise This test would
not be able to determine the sensitivity of the RCD nor the time taken for it to trip
iv Test Method 2
1048766 Use a RCD Tester
This equipment is equipped with a 13A plug which can be connected to a 13A socket outlet Select the
RCD sensitivity to be the same as the sensitivity of the RCD to be tested to determine if the RCD can
trip The time to trip shall not exceed 40 mS
1048766 Test method ndash
a) Position the selection switch in accordance with the sensitivity of the RCD used
Example 100 mA 01 A
b) Position the operations switch to lsquoNo Triprsquo (frac12 Rated mA = 50) connect the 3 pin plug to
the 13A socket outlet
c) Switch on the 13A socket outlet ndash ensure that the P-N and P-E lights light up This shows that
the polarity is correct (Note if both the lights as above do not light up the test cannot be
continued)
d) Press the test button ndash the reading shows less than 200 millisecond and simultaneously the
lsquotestrsquo light lights up and the P-N and P-E lights do not light up At that instant the RCD will
not trip
e) Move the selection switch to 180o (+ve wave) ndash repeat steps (d) and (e) = 100)
f) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
g) Move the selection switch to 0o (-ve wave)
h) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
i) The above test is repeated until a near correct reading is obtained
j) Record the test results
k) Change the operations switch to lsquoFast Triprsquo and press the test button ndash RCD will trip within a
time not exceeding 40 mS
l) Repeat a number of times at 0o or 180o
72 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 9 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (DC)
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
73 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Start stop button 240Vac 5A 2
9 Filament lamp (Bulb ) 240Vac 40W 3
10 Overload Relay 415V 20A 3
11 Three phase induction motor 5 hp 3
12 Single phase step down transformer 2500VA 1
13 Single core PVC insulated Cable 1mm 2 As required
14 Single core PVC insulated Cable 25mm 2 As required
15 DIN rail 35 mm As required
16 PVC type Cable tray 50 mm x 50 mm As required
17 Cable ties 4 ldquo As required
18 Flexible wires 05 mm As required
19 PVC Connectors 5 A amp 20 A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the schematic
diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a optional exercise
i Simple DOL starter
ii Forward reverse DOL starter
iii Forward Reverse Dahlander motor
iv Three motors operated in sequence by DOL starter operated by manual push
button or time delay relay
74 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
a One loop per-cycle
b Continuous operation in a loop
c optional circuit design to represent the same task
v Only one out of three motors to be operated at a time (quiz)
4 Test the functionality of completed project
LESSON 10 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (AC)
75 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 1
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Lamp point 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
76 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
11 Overload Relay 415V 20A 3
12 Three phase induction
motor
5 hp 3
13 Single core PVC insulated
Cable
1mm 2 As required
14 Single core PVC insulated
Cable
25mm 2 As required
15 DIN rail 35 mm As required
16 PVC type Cable tray 50 mm x 50 mm As required
17 Cable ties 4 ldquo As required
18 Flexible wires 05 mm As required
19 PVC Connectors 5 A amp 20 A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the
schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram optional exercise
4 Simple DOL starter
5 Forward reverse DOL starter
6 Test the functionality of completed project
77 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 1
78 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
cm
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Indicating light 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
11 Overload Relay 415V 20A 3
12 Three phase induction motor 5 hp 3
13 Single phase step down
transformer
2500VA 1
14 Single core PVC insulated
Cable
1mm 2 As required
15 Single core PVC insulated
Cable
25mm 2 As required
16 DIN rail 35 mm As required
17 PVC type Cable tray 50 mm x 50 mm As required
18 Cable ties 4 ldquo As required
19 Flexible wires 05 mm As required
20 PVC Connectors 5 A amp 20 A 240 V As required
21 Single pole MCB 6A 240 V 1
22 Single pole MCB 2A 240 V 1
23 Triple pole MCB 20A 415 V 1
24 Mounting board 30 cm x 40 cm x 3
cm
1
25 Relay cw 11 pin socket 10 A 240 Vac 2
26 Time delay relay 10 A 240 Vac 3
27 Triple pole Contactor 20A 240Vac 3
28 Batten type Lamp holder 240Vac 10 A 3
29 Start stop button 240Vac 10A 2
30 Indicating light (Bulb ) 240Vac 25W 3
31 Overload Relay 415V 20A 1
32 Three phase dahlander type
induction motor
5 hp 1
33 Single phase step down
transformer
24024Vac
2500VA
1
79 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
34 Single core PVC insulated
Cable
1mm 2 As required
35 Single core PVC insulated
Cable
25mm 2 As required
36 DIN rail 35 mm As required
37 PVC type Cable tray 50 mm x 50 mm As required
38 Cable ties 4 ldquo As required
39 Flexible wires 075 mm As required
40 PVC Connectors 5 A amp 20 A 240 V As required
41 Terminal block 20A 240Vac As required
Procedures
5 Identify each component according to specification and quantity required from the schematic
diagram attached
6 Test the functionality of each component by using multi-meter or power supply whichever
applicable
7 Wire component according to circuit diagram
8 Three motors operated in sequence by DOL starter operated by manual push button or time
delay relay
a One loop per-cycle
b Continuous operation in a loop
c optional circuit design to represent the same task
d Only one out of three motors to be operated at a time (quiz)
9 Test the functionality of completed project
80 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
BASIC DESIGN INDUSTRIAL MOTOR CONTROL (SEQUENCE CONTROL)
THREE PHASE INDUCTION MOTOR OPERATED IN SEQUENCE BY DIRECT ON LINE
STARTER
LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
81 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
82 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Lcd lamp indicator 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
11 Overload Relay 415V 20A 3
12 Three phase induction motor 5 hp 3
13 Single phase step down transformer 2500VA 1
14 Single core PVC insulated Cable 1mm 2 As required
15 Single core PVC insulated Cable 25mm 2 As required
16 DIN rail 35 mm As required
17 PVC type Cable tray 50 mm x 50 mm As required
18 Cable ties 4 ldquo As required
19 Flexible wires 1 mm Oslash As required
20 PVC Terminal block 10A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the schematic
diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a optional exercise
i Forward Reverse dahlander motor
4 Test the functionality of completed project
83 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
THREE PHASE DAHLANDER TYPE INDUCTION MOTOR OPERATED FORWARD AND
REVERSE OPERATION BY DIRECT ON LINE STARTER
84 ndash 99EASYTECH ENTERPRISE
LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
Introduction
If a motors windings are connected in the star configuration any two phases will be in series across
the supply and hence the line current will be smaller(by 577) than if the windings were connected in
the delta arrangement
Hence larger-type motors with heavy starting currents are first connected in star and then when the
starting currents fall in delta This of course means that all six of the ends of the windings must be
brought to terminations outside the casing (Fig 833)
EZTECH
EZTECH ELECTRICAL INSTALLATION GUIDE
The automatic version of this starter incorporates a timing relay which automatically changes the
connections from star to delta Figs 834 and 835 show the wiring and schematic diagrams for a star
delta starter
Objectives
1 Identify component and the specification
2 Design forward reverse star delta starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
2 ndash 99EASYTECH ENTERPRISE
REV -C
LEGENDMCCB Moulded Case Circuit BreakerTOR Thermal Over Load RelayFOW-C Mains Forward ContactorREV-C Mains Reverse ContactorDC Delta ContactorSC Star ContactorS-SW Mains Selector Switch
SC
V2
W2
U2
DC
V1
W1
U1
TOR
TOR
FOW-C
30A MCCB
TOR
MAIN CIRCUIT FORWARD REVERSE STAR DELTA
RYBN S
-SW
3 PHASEINDUCTION MOTOR
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Relay 10 A 240V 3
5 Triple pole Contactor
6 cw NO NC auxiliary contact
240Vac 20 A 4
7 Overload Relay 415 V 1
8 LED indicator 240vac 5 A 4
9 Start stop button 240Vac 5A 2
10 DIN rail 35 mm As required
11 Flexible wires 1 mm As required
12 Single core PVC insulated
wire
25 mm As required
13 Terminal block 20 A As required
14 Squirrel cage motor 5kW 1
15 5 pin plug and socket 415V 20A 1
16 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
3 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
a Manual star delta
b Manual Forward reverse star delta starter
c Automatic star delta starter
d Automatic Forward reverse star delta starter
4 Test the functionality of completed project
4 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
Objectives
1 Identify component and the specification
2 Design auto transformer starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
5 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Autotransformer starter is used to start a 3 phase induction motor that has a rating between 10 to 15 hp
6 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Autotransformer set 10Kw 415 V 50 Hz 1
5 Triple pole Contactor 240Vac 4
6 Batten type Lamp holder 240 Vac 105 A 4
7 Start stop button 240Vac 10A 4
8 Filament lamp (Bulb ) 240Vac 40W 4
9 DIN rail 35 mm As required
10 Flexible wires 1 mm As required
7 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
11 Single core PVC insulated
wire
25 mm As required
12 Terminal block 20 A As required
13 Squirrel cage motor 10kW 1
14 5 pin plug and socket 415V 20A 1
15 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a open transient autotransformer starter
b close transient autotransformer starter
c Forward reverse autotransformer starter
4 Test the functionality of completed project
8 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
Objectives
1 Identify component and the specification
2 Design rotor resistance starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
9 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Rotor Resistor set 10kW 1
5 Triple pole Contactor 240Vac 20A 4
6 Indicating light 240vac 5 A 4
7 Start stop push button 240Vac 5A 4
8 DIN rail 35 mm As required
9 Flexible wires 1 mm 2 As required
10 Single core PVC insulated wire 25 mm 2 As required
11 Terminal block 20 A As required
12 Slip Ring motor 10kW 1
13 5 pin round 3 phase socket 415V 20A 1
14 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
10 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
4 Test the functionality of completed project
a Dead circuit test b Life circuit test
5 Measure starting and running Amps
LESSON 16
TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
An installation in general will suffer damage
Damage usually occurs on the electric motor control as follows
1 Damage to the main circuit
2 Damage to the control circuit
The cause of the damage
i Overcurrent overload short circuit
ii Leakage current to ground
iii Equipment malfunction
iv The main control circuit
a Trip of main circuit protection devices fire
b Defect of motor terminal such as short circuit fire loose
v The control circuit is not functioning -
a contactor relay relay time overload relay does not work damaged burned
b Loose cable connection disconnected
Detecting and Repairing Damage
Examples of damage are as follows
i Motor does not work
ii Motor function and overload relay trips
iii Motor function but only partially functional control circuit
Methods of detecting damage
Among the known methods necessary to detect damage are as follows
1 Turn off the electricity at the main switch (main switch) in order to avoid any danger during the
work carried out to detect damage
2 Check all the protective gear that controls the motor control main circuit
11 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
3 Make sure the damage function control circuit
4 Check the control circuit according to the schematic circuit diagram of the motor control
5 Check the operation of the control circuit
Note
Use wiring that has been installed on the SYSTEM OF MOTOR CONTROL BOARD by Forward
Reverse control circuit for Star Delta to test and look for damage
SELF-ASSESSMENT QUESTIONS
1 (a) Explain what is meant by the term lsquoback emfrsquo in a motor
(b) Outline the basic differences between series shunt and compound wound dc motors
2 (a) With the aid of diagrams explain how the speed of series shunt and compound-wound motors
may be controlled
(b) A 440V dc shunt-wound motor has a field resistance of 200R and an armature resistance of 06 R
When its speed is 20 rev d second the current drawn from the supply is 122A Calculate its back
emf at this speed If the speed were decreased to 19 revssecond the field flux remaining unchanged
calculate the new back emf and the new armature current
3 A load of 64 kW at 240 V is supplied from the terminals of a shunt-wound dc generator The field
resistance is 180 A Calculate the armature current
4 (a) Explain with the aid of a diagram how a rotating magnetic field may be
(b) What is meant by lsquosynchronous speedrsquo
Calculate the synchronous obtained speed of a 12 pole motor if the supply frequency is 50Hz
5 (a) Explain the action of a synchronous motor
(b) What methods are available to start a synchronous motor Explain with diagrams
6 (a) Explain the action of a cage induction motor
(b) What is meant by the term lsquosliprsquo
Calculate the percentage slip of a six pole induction motor running at 162 revssecond from a 50 Hz
supply
7 Describe with sketches three different ways of starting a single-phase induction motor
12 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
8 Explain with the aid of a sketch the action of a three-phase DOL starter
What are dashpots used for How are remote start and stop buttons connected
9 A I0 kW 240V 50Hz single-phase cage rotor induction motor is 85efficient and has a PF of 068
lagging Calculate the motor current and the value of capacitor required to raise the PF to 093
lagging
10 Calculate the torque developed by an 18 kW four-pole induction motor run at 35 slip from a
50Hz supply
APPENDIX 1
13 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 11
14 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 111
Attachment Reference
httpswwwtlc-directcoukBook621htm
httpwwwstgovmyindexphpms
15 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Insulation resitance test
62 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
INSULATION RESISTANCE TEST BETWEEN CONDUCTORS AND OPPOSITE POLARITY
Polarity Testi Ensure that each fuse or single pole control and protection device is connected only in the phase
conductor
ii Intermediate contact of Edison screw lamp holder is connected to the phase conductor
iii Ensure that phase neutral and earth conductors at socket outlets are connected at the correct
terminals
iv Test Equipment ndash Multimeter (Ohm range) or Ohm meter
v Test Method
1 1048766 Switch off Main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in Figure 85
63 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
5 1048766 Test switches and single phase control devices at the phase conductors
6 1048766 Test socket outlet connection sources
7 1048766 Test Edison screw lamp holder connections
8 1048766 Meter reading value shall be less than 1 Ω
64 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Polarity test
65 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Earth Electrode Resistance Testi To test the earth electrode resistance
ii To ascertain the suitability of the location of the electrode
iii To ensure that the electrode is not buried within the resistance area of another electrode
iv Test equipment ndash Earth Resistance Tester
v Test method -
1 1048766 Terminal rsquoErsquo is connected to the electrode to be tested (green conductor)
2 1048766 Terminal lsquoPrsquo is connected to the potential spike (yellow conductor) at a distance of 10
meters from the earth electrode
3 1048766 Terminal lsquoCrsquo is connected to the current spike (red conductor) at a distance of 20 meters
from the earth electrode
Earth Electrode Resistance Measurement Method (Figure 86)
This test must be repeated at least three times to ensure that the reading is not affected by interacting
earthing regions
i Record the first reading (Z1) Example Z1 = 10 Ω
ii Move the voltage spike to a distance of 6 meters from the original position Record the second
reading (Z2 ) Example Z2 = 10 Ω
iii Move the voltage spike to a distance of 6 meters from the original position Record the third
reading (Z3) Example Z3 = 10 Ω
66 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Residual Current Device Testi Ensure that the residual current device (RCD) trips within the set time on the occurrence of current
leakage to earth
ii Test Equipment ndash RCD Tester RCCB Tester
iii Test Method 1
1 1048766 Use the Trip Test Button
2 1048766 Press the trip button found on the RCD to determine if it trips or otherwise This test would
not be able to determine the sensitivity of the RCD nor the time taken for it to trip
iv Test Method 2
i 1048766 Use a RCD Tester
ii This equipment is equipped with a 13A plug which can be connected to a 13A socket outlet
Select the RCD sensitivity to be the same as the sensitivity of the RCD to be tested to
determine if the RCD can trip The time to trip shall not exceed 40 mS
iii 1048766 Test method ndash
a) Position the selection switch in accordance with the sensitivity of the RCD used
Example 100 mA 01 A
b) Position the operations switch to lsquoNo Triprsquo (frac12 Rated mA = 50) connect the 3 pin plug to
the 13A socket outlet
67 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
c) Switch on the 13A socket outlet ndash ensure that the P-N and P-E lights light up
This shows that the polarity is correct (Note if both the lights as above do not light up the test cannot
be continued)
d) Press the test button ndash the reading shows less than 200 mS and simultaneously the lsquotestrsquo light lights
up and the P-N and P-E lights do not light up At that instant the RCD will not trip
e) Move the selection switch to 180o (+ve wave) ndash repeat steps (d) and (e) Move the operations
switch to lsquoTriprsquo (Rated mA = 100)
g) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200mS
h) Move the selection switch to 0o (-ve wave)
i) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
j) The above test is repeated until a near correct reading is obtained
k) Record the test results
l) Change the operations switch to lsquoFast Triprsquo and press the test button ndash RCD will trip within a
time not exceeding 40 millisecond
m) Repeat a number of times at 0o or 180o
On completion of a wiring installation a number of tests on the installation have to be conducted to
ascertain that the wiring circuits and connected appliances are safe for use Prior to carrying out the
tests an inspection has to be done the following tests shall be conducted
i Continuity Test
ii Insulation Resistance Test
iii Polarity Test
iv Earth Electrode Resistance test and
v Residual Current Device Test
821 Continuity Test
There are 3 main types of continuity tests for the final circuits-
i Protection Conductor Continuity Test
ii Final Ring Circuit Conductor Continuity Test
68 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
iii Live and Neutral Conductor Continuity Test
a) Protection Conductor Continuity Test
bull To ascertain that all protection conductors are connected in the correct and effective manner
bull Test equipment ndash Multimeter (Ohm range) or Ohm meter
bull Test Method
1 1048766 Ensure that the main switch RCD and MCB are open circuited (switched off) and all loads are
disconnected
2 1048766 Connected the test leads as in the Figure 81
3 1048766 The meter reading shall be less than 1 Ω
Final Ring Circuit Conductor Continuity Test
bull To ensure that all conductors around the ring circuit have continuity
bull Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
bull Test Method
1 1048766 Disconnect both the supply source live conductors from the MCB the neutral conductor
from the neutral terminals and the earth conductor from the earth terminal in the distribution
fuse box
2 1048766 Connect the test leads as in the Figure 82 (EE)
3 1048766 Repeat the procedure for (L-L) and (N-N)
4 1048766 The meter reading value shall be less than 1 ohm Figure 82 - Final Ring Circuit Conductor
Continuity Test Ohm Meter
Disconnect both the supply source cables from mcbfuse
Take readings at earth conductors of both sources and note resistance readings
Live and Neutral Conductor Continuity Test
1 To ensure that each conductor in the circuit has continuity
2 Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
3 Test Method
1 1048766 Switch off the Main switch RCD and MCB
2 1048766 Disconnect all loads
3 1048766 Switch on all switches in the circuit
4 1048766 Disconnect the fusesfinal circuit breakers and close the circuit
5 1048766 Carry out the test as shown in Figure 83
6 1048766 The meter reading value shall be less than 1 ohm Figure 83 - Live and Neutral
Conductor Continuity Test Ohm Meter
Insulation Resistance Test
69 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
i Ensure that there is no leakage current between phase conductors phase and neutral conductors and
phase conductor and earth
ii Test the strength of the cable insulation
iii Test Equipment ndash Insulation Resistance Tester Operating voltage is 250VDC or 500VDC
iv Test Method
1 1048766 Switch off main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in the Table below
5 1048766 Meter reading value shall be less than 1 Megaohm
Polarity Test
i Ensure that each fuse or single pole control and protection device is connected only in the phase
conductor
ii Intermediate contact of Edison screw lamp holder is connected to the phase conductor
iii Ensure that phase neutral and earth conductors at socket outlets are connected at the correct
terminals
iv Test Equipment ndash Multimeter (Ohm range) or Ohm meter
v Test Method
1 1048766 Switch off Main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in Figure 85
5 1048766 Test switches and single phase control devices at the phase conductors
6 1048766 Test socket outlet connection sources
7 1048766 Test Edison screw lamp holder connections
8 1048766 Meter reading value shall be less than 1 Ω
Earth Electrode Resistance Test
i To test the earth electrode resistance
70 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
ii To ascertain the suitability of the location of the electrode
iii To ensure that the electrode is not buried within the resistance area of another electrode
iv Test equipment ndash Earth Resistance Tester
v Test method -
1 1048766 Terminal rsquoErsquo is connected to the electrode to be tested (green conductor)
2 1048766 Terminal lsquoPrsquo is connected to the potential spike (yellow conductor) at a distance of 10
meters from the earth electrode
3 1048766 Terminal lsquoCrsquo is connected to the current spike (red conductor) at a distance of 20 meters
from the earth electrode E P C Electrode 10 meter 10 meter
Figure 86 ndash Earth Electrode Resistance Measurement Test Equipment
Earth Electrode Resistance Measurement Method (Figure 86)
This test must be repeated at least three times to ensure that the reading is not affected by interacting
earthing regions
i Record the first reading (Z1) Example Z1 = 10 Ω
ii Move the voltage spike to a distance of 6 meters from the original position Record the second
reading (Z2) Example Z2 = 10 Ω
iii Move the voltage spike to a distance of 6 meters from the original position Record the third
reading (Z3)
Example Z3 = 10 Ω
Residual Current Device Test
71 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
i Ensure that the residual current device (RCD) trips within the set time on the occurrence of current
leakage to earth
ii Test Equipment ndash RCD Tester RCCB Tester
iii Test Method 1
1 1048766 Use the Trip Test Button
2 1048766 Press the trip button found on the RCD to determine if it trips or otherwise This test would
not be able to determine the sensitivity of the RCD nor the time taken for it to trip
iv Test Method 2
1048766 Use a RCD Tester
This equipment is equipped with a 13A plug which can be connected to a 13A socket outlet Select the
RCD sensitivity to be the same as the sensitivity of the RCD to be tested to determine if the RCD can
trip The time to trip shall not exceed 40 mS
1048766 Test method ndash
a) Position the selection switch in accordance with the sensitivity of the RCD used
Example 100 mA 01 A
b) Position the operations switch to lsquoNo Triprsquo (frac12 Rated mA = 50) connect the 3 pin plug to
the 13A socket outlet
c) Switch on the 13A socket outlet ndash ensure that the P-N and P-E lights light up This shows that
the polarity is correct (Note if both the lights as above do not light up the test cannot be
continued)
d) Press the test button ndash the reading shows less than 200 millisecond and simultaneously the
lsquotestrsquo light lights up and the P-N and P-E lights do not light up At that instant the RCD will
not trip
e) Move the selection switch to 180o (+ve wave) ndash repeat steps (d) and (e) = 100)
f) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
g) Move the selection switch to 0o (-ve wave)
h) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
i) The above test is repeated until a near correct reading is obtained
j) Record the test results
k) Change the operations switch to lsquoFast Triprsquo and press the test button ndash RCD will trip within a
time not exceeding 40 mS
l) Repeat a number of times at 0o or 180o
72 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 9 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (DC)
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
73 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Start stop button 240Vac 5A 2
9 Filament lamp (Bulb ) 240Vac 40W 3
10 Overload Relay 415V 20A 3
11 Three phase induction motor 5 hp 3
12 Single phase step down transformer 2500VA 1
13 Single core PVC insulated Cable 1mm 2 As required
14 Single core PVC insulated Cable 25mm 2 As required
15 DIN rail 35 mm As required
16 PVC type Cable tray 50 mm x 50 mm As required
17 Cable ties 4 ldquo As required
18 Flexible wires 05 mm As required
19 PVC Connectors 5 A amp 20 A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the schematic
diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a optional exercise
i Simple DOL starter
ii Forward reverse DOL starter
iii Forward Reverse Dahlander motor
iv Three motors operated in sequence by DOL starter operated by manual push
button or time delay relay
74 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
a One loop per-cycle
b Continuous operation in a loop
c optional circuit design to represent the same task
v Only one out of three motors to be operated at a time (quiz)
4 Test the functionality of completed project
LESSON 10 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (AC)
75 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 1
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Lamp point 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
76 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
11 Overload Relay 415V 20A 3
12 Three phase induction
motor
5 hp 3
13 Single core PVC insulated
Cable
1mm 2 As required
14 Single core PVC insulated
Cable
25mm 2 As required
15 DIN rail 35 mm As required
16 PVC type Cable tray 50 mm x 50 mm As required
17 Cable ties 4 ldquo As required
18 Flexible wires 05 mm As required
19 PVC Connectors 5 A amp 20 A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the
schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram optional exercise
4 Simple DOL starter
5 Forward reverse DOL starter
6 Test the functionality of completed project
77 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 1
78 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
cm
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Indicating light 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
11 Overload Relay 415V 20A 3
12 Three phase induction motor 5 hp 3
13 Single phase step down
transformer
2500VA 1
14 Single core PVC insulated
Cable
1mm 2 As required
15 Single core PVC insulated
Cable
25mm 2 As required
16 DIN rail 35 mm As required
17 PVC type Cable tray 50 mm x 50 mm As required
18 Cable ties 4 ldquo As required
19 Flexible wires 05 mm As required
20 PVC Connectors 5 A amp 20 A 240 V As required
21 Single pole MCB 6A 240 V 1
22 Single pole MCB 2A 240 V 1
23 Triple pole MCB 20A 415 V 1
24 Mounting board 30 cm x 40 cm x 3
cm
1
25 Relay cw 11 pin socket 10 A 240 Vac 2
26 Time delay relay 10 A 240 Vac 3
27 Triple pole Contactor 20A 240Vac 3
28 Batten type Lamp holder 240Vac 10 A 3
29 Start stop button 240Vac 10A 2
30 Indicating light (Bulb ) 240Vac 25W 3
31 Overload Relay 415V 20A 1
32 Three phase dahlander type
induction motor
5 hp 1
33 Single phase step down
transformer
24024Vac
2500VA
1
79 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
34 Single core PVC insulated
Cable
1mm 2 As required
35 Single core PVC insulated
Cable
25mm 2 As required
36 DIN rail 35 mm As required
37 PVC type Cable tray 50 mm x 50 mm As required
38 Cable ties 4 ldquo As required
39 Flexible wires 075 mm As required
40 PVC Connectors 5 A amp 20 A 240 V As required
41 Terminal block 20A 240Vac As required
Procedures
5 Identify each component according to specification and quantity required from the schematic
diagram attached
6 Test the functionality of each component by using multi-meter or power supply whichever
applicable
7 Wire component according to circuit diagram
8 Three motors operated in sequence by DOL starter operated by manual push button or time
delay relay
a One loop per-cycle
b Continuous operation in a loop
c optional circuit design to represent the same task
d Only one out of three motors to be operated at a time (quiz)
9 Test the functionality of completed project
80 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
BASIC DESIGN INDUSTRIAL MOTOR CONTROL (SEQUENCE CONTROL)
THREE PHASE INDUCTION MOTOR OPERATED IN SEQUENCE BY DIRECT ON LINE
STARTER
LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
81 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
82 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Lcd lamp indicator 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
11 Overload Relay 415V 20A 3
12 Three phase induction motor 5 hp 3
13 Single phase step down transformer 2500VA 1
14 Single core PVC insulated Cable 1mm 2 As required
15 Single core PVC insulated Cable 25mm 2 As required
16 DIN rail 35 mm As required
17 PVC type Cable tray 50 mm x 50 mm As required
18 Cable ties 4 ldquo As required
19 Flexible wires 1 mm Oslash As required
20 PVC Terminal block 10A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the schematic
diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a optional exercise
i Forward Reverse dahlander motor
4 Test the functionality of completed project
83 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
THREE PHASE DAHLANDER TYPE INDUCTION MOTOR OPERATED FORWARD AND
REVERSE OPERATION BY DIRECT ON LINE STARTER
84 ndash 99EASYTECH ENTERPRISE
LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
Introduction
If a motors windings are connected in the star configuration any two phases will be in series across
the supply and hence the line current will be smaller(by 577) than if the windings were connected in
the delta arrangement
Hence larger-type motors with heavy starting currents are first connected in star and then when the
starting currents fall in delta This of course means that all six of the ends of the windings must be
brought to terminations outside the casing (Fig 833)
EZTECH
EZTECH ELECTRICAL INSTALLATION GUIDE
The automatic version of this starter incorporates a timing relay which automatically changes the
connections from star to delta Figs 834 and 835 show the wiring and schematic diagrams for a star
delta starter
Objectives
1 Identify component and the specification
2 Design forward reverse star delta starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
2 ndash 99EASYTECH ENTERPRISE
REV -C
LEGENDMCCB Moulded Case Circuit BreakerTOR Thermal Over Load RelayFOW-C Mains Forward ContactorREV-C Mains Reverse ContactorDC Delta ContactorSC Star ContactorS-SW Mains Selector Switch
SC
V2
W2
U2
DC
V1
W1
U1
TOR
TOR
FOW-C
30A MCCB
TOR
MAIN CIRCUIT FORWARD REVERSE STAR DELTA
RYBN S
-SW
3 PHASEINDUCTION MOTOR
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Relay 10 A 240V 3
5 Triple pole Contactor
6 cw NO NC auxiliary contact
240Vac 20 A 4
7 Overload Relay 415 V 1
8 LED indicator 240vac 5 A 4
9 Start stop button 240Vac 5A 2
10 DIN rail 35 mm As required
11 Flexible wires 1 mm As required
12 Single core PVC insulated
wire
25 mm As required
13 Terminal block 20 A As required
14 Squirrel cage motor 5kW 1
15 5 pin plug and socket 415V 20A 1
16 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
3 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
a Manual star delta
b Manual Forward reverse star delta starter
c Automatic star delta starter
d Automatic Forward reverse star delta starter
4 Test the functionality of completed project
4 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
Objectives
1 Identify component and the specification
2 Design auto transformer starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
5 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Autotransformer starter is used to start a 3 phase induction motor that has a rating between 10 to 15 hp
6 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Autotransformer set 10Kw 415 V 50 Hz 1
5 Triple pole Contactor 240Vac 4
6 Batten type Lamp holder 240 Vac 105 A 4
7 Start stop button 240Vac 10A 4
8 Filament lamp (Bulb ) 240Vac 40W 4
9 DIN rail 35 mm As required
10 Flexible wires 1 mm As required
7 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
11 Single core PVC insulated
wire
25 mm As required
12 Terminal block 20 A As required
13 Squirrel cage motor 10kW 1
14 5 pin plug and socket 415V 20A 1
15 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a open transient autotransformer starter
b close transient autotransformer starter
c Forward reverse autotransformer starter
4 Test the functionality of completed project
8 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
Objectives
1 Identify component and the specification
2 Design rotor resistance starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
9 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Rotor Resistor set 10kW 1
5 Triple pole Contactor 240Vac 20A 4
6 Indicating light 240vac 5 A 4
7 Start stop push button 240Vac 5A 4
8 DIN rail 35 mm As required
9 Flexible wires 1 mm 2 As required
10 Single core PVC insulated wire 25 mm 2 As required
11 Terminal block 20 A As required
12 Slip Ring motor 10kW 1
13 5 pin round 3 phase socket 415V 20A 1
14 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
10 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
4 Test the functionality of completed project
a Dead circuit test b Life circuit test
5 Measure starting and running Amps
LESSON 16
TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
An installation in general will suffer damage
Damage usually occurs on the electric motor control as follows
1 Damage to the main circuit
2 Damage to the control circuit
The cause of the damage
i Overcurrent overload short circuit
ii Leakage current to ground
iii Equipment malfunction
iv The main control circuit
a Trip of main circuit protection devices fire
b Defect of motor terminal such as short circuit fire loose
v The control circuit is not functioning -
a contactor relay relay time overload relay does not work damaged burned
b Loose cable connection disconnected
Detecting and Repairing Damage
Examples of damage are as follows
i Motor does not work
ii Motor function and overload relay trips
iii Motor function but only partially functional control circuit
Methods of detecting damage
Among the known methods necessary to detect damage are as follows
1 Turn off the electricity at the main switch (main switch) in order to avoid any danger during the
work carried out to detect damage
2 Check all the protective gear that controls the motor control main circuit
11 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
3 Make sure the damage function control circuit
4 Check the control circuit according to the schematic circuit diagram of the motor control
5 Check the operation of the control circuit
Note
Use wiring that has been installed on the SYSTEM OF MOTOR CONTROL BOARD by Forward
Reverse control circuit for Star Delta to test and look for damage
SELF-ASSESSMENT QUESTIONS
1 (a) Explain what is meant by the term lsquoback emfrsquo in a motor
(b) Outline the basic differences between series shunt and compound wound dc motors
2 (a) With the aid of diagrams explain how the speed of series shunt and compound-wound motors
may be controlled
(b) A 440V dc shunt-wound motor has a field resistance of 200R and an armature resistance of 06 R
When its speed is 20 rev d second the current drawn from the supply is 122A Calculate its back
emf at this speed If the speed were decreased to 19 revssecond the field flux remaining unchanged
calculate the new back emf and the new armature current
3 A load of 64 kW at 240 V is supplied from the terminals of a shunt-wound dc generator The field
resistance is 180 A Calculate the armature current
4 (a) Explain with the aid of a diagram how a rotating magnetic field may be
(b) What is meant by lsquosynchronous speedrsquo
Calculate the synchronous obtained speed of a 12 pole motor if the supply frequency is 50Hz
5 (a) Explain the action of a synchronous motor
(b) What methods are available to start a synchronous motor Explain with diagrams
6 (a) Explain the action of a cage induction motor
(b) What is meant by the term lsquosliprsquo
Calculate the percentage slip of a six pole induction motor running at 162 revssecond from a 50 Hz
supply
7 Describe with sketches three different ways of starting a single-phase induction motor
12 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
8 Explain with the aid of a sketch the action of a three-phase DOL starter
What are dashpots used for How are remote start and stop buttons connected
9 A I0 kW 240V 50Hz single-phase cage rotor induction motor is 85efficient and has a PF of 068
lagging Calculate the motor current and the value of capacitor required to raise the PF to 093
lagging
10 Calculate the torque developed by an 18 kW four-pole induction motor run at 35 slip from a
50Hz supply
APPENDIX 1
13 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 11
14 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 111
Attachment Reference
httpswwwtlc-directcoukBook621htm
httpwwwstgovmyindexphpms
15 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
INSULATION RESISTANCE TEST BETWEEN CONDUCTORS AND OPPOSITE POLARITY
Polarity Testi Ensure that each fuse or single pole control and protection device is connected only in the phase
conductor
ii Intermediate contact of Edison screw lamp holder is connected to the phase conductor
iii Ensure that phase neutral and earth conductors at socket outlets are connected at the correct
terminals
iv Test Equipment ndash Multimeter (Ohm range) or Ohm meter
v Test Method
1 1048766 Switch off Main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in Figure 85
63 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
5 1048766 Test switches and single phase control devices at the phase conductors
6 1048766 Test socket outlet connection sources
7 1048766 Test Edison screw lamp holder connections
8 1048766 Meter reading value shall be less than 1 Ω
64 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Polarity test
65 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Earth Electrode Resistance Testi To test the earth electrode resistance
ii To ascertain the suitability of the location of the electrode
iii To ensure that the electrode is not buried within the resistance area of another electrode
iv Test equipment ndash Earth Resistance Tester
v Test method -
1 1048766 Terminal rsquoErsquo is connected to the electrode to be tested (green conductor)
2 1048766 Terminal lsquoPrsquo is connected to the potential spike (yellow conductor) at a distance of 10
meters from the earth electrode
3 1048766 Terminal lsquoCrsquo is connected to the current spike (red conductor) at a distance of 20 meters
from the earth electrode
Earth Electrode Resistance Measurement Method (Figure 86)
This test must be repeated at least three times to ensure that the reading is not affected by interacting
earthing regions
i Record the first reading (Z1) Example Z1 = 10 Ω
ii Move the voltage spike to a distance of 6 meters from the original position Record the second
reading (Z2 ) Example Z2 = 10 Ω
iii Move the voltage spike to a distance of 6 meters from the original position Record the third
reading (Z3) Example Z3 = 10 Ω
66 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Residual Current Device Testi Ensure that the residual current device (RCD) trips within the set time on the occurrence of current
leakage to earth
ii Test Equipment ndash RCD Tester RCCB Tester
iii Test Method 1
1 1048766 Use the Trip Test Button
2 1048766 Press the trip button found on the RCD to determine if it trips or otherwise This test would
not be able to determine the sensitivity of the RCD nor the time taken for it to trip
iv Test Method 2
i 1048766 Use a RCD Tester
ii This equipment is equipped with a 13A plug which can be connected to a 13A socket outlet
Select the RCD sensitivity to be the same as the sensitivity of the RCD to be tested to
determine if the RCD can trip The time to trip shall not exceed 40 mS
iii 1048766 Test method ndash
a) Position the selection switch in accordance with the sensitivity of the RCD used
Example 100 mA 01 A
b) Position the operations switch to lsquoNo Triprsquo (frac12 Rated mA = 50) connect the 3 pin plug to
the 13A socket outlet
67 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
c) Switch on the 13A socket outlet ndash ensure that the P-N and P-E lights light up
This shows that the polarity is correct (Note if both the lights as above do not light up the test cannot
be continued)
d) Press the test button ndash the reading shows less than 200 mS and simultaneously the lsquotestrsquo light lights
up and the P-N and P-E lights do not light up At that instant the RCD will not trip
e) Move the selection switch to 180o (+ve wave) ndash repeat steps (d) and (e) Move the operations
switch to lsquoTriprsquo (Rated mA = 100)
g) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200mS
h) Move the selection switch to 0o (-ve wave)
i) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
j) The above test is repeated until a near correct reading is obtained
k) Record the test results
l) Change the operations switch to lsquoFast Triprsquo and press the test button ndash RCD will trip within a
time not exceeding 40 millisecond
m) Repeat a number of times at 0o or 180o
On completion of a wiring installation a number of tests on the installation have to be conducted to
ascertain that the wiring circuits and connected appliances are safe for use Prior to carrying out the
tests an inspection has to be done the following tests shall be conducted
i Continuity Test
ii Insulation Resistance Test
iii Polarity Test
iv Earth Electrode Resistance test and
v Residual Current Device Test
821 Continuity Test
There are 3 main types of continuity tests for the final circuits-
i Protection Conductor Continuity Test
ii Final Ring Circuit Conductor Continuity Test
68 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
iii Live and Neutral Conductor Continuity Test
a) Protection Conductor Continuity Test
bull To ascertain that all protection conductors are connected in the correct and effective manner
bull Test equipment ndash Multimeter (Ohm range) or Ohm meter
bull Test Method
1 1048766 Ensure that the main switch RCD and MCB are open circuited (switched off) and all loads are
disconnected
2 1048766 Connected the test leads as in the Figure 81
3 1048766 The meter reading shall be less than 1 Ω
Final Ring Circuit Conductor Continuity Test
bull To ensure that all conductors around the ring circuit have continuity
bull Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
bull Test Method
1 1048766 Disconnect both the supply source live conductors from the MCB the neutral conductor
from the neutral terminals and the earth conductor from the earth terminal in the distribution
fuse box
2 1048766 Connect the test leads as in the Figure 82 (EE)
3 1048766 Repeat the procedure for (L-L) and (N-N)
4 1048766 The meter reading value shall be less than 1 ohm Figure 82 - Final Ring Circuit Conductor
Continuity Test Ohm Meter
Disconnect both the supply source cables from mcbfuse
Take readings at earth conductors of both sources and note resistance readings
Live and Neutral Conductor Continuity Test
1 To ensure that each conductor in the circuit has continuity
2 Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
3 Test Method
1 1048766 Switch off the Main switch RCD and MCB
2 1048766 Disconnect all loads
3 1048766 Switch on all switches in the circuit
4 1048766 Disconnect the fusesfinal circuit breakers and close the circuit
5 1048766 Carry out the test as shown in Figure 83
6 1048766 The meter reading value shall be less than 1 ohm Figure 83 - Live and Neutral
Conductor Continuity Test Ohm Meter
Insulation Resistance Test
69 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
i Ensure that there is no leakage current between phase conductors phase and neutral conductors and
phase conductor and earth
ii Test the strength of the cable insulation
iii Test Equipment ndash Insulation Resistance Tester Operating voltage is 250VDC or 500VDC
iv Test Method
1 1048766 Switch off main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in the Table below
5 1048766 Meter reading value shall be less than 1 Megaohm
Polarity Test
i Ensure that each fuse or single pole control and protection device is connected only in the phase
conductor
ii Intermediate contact of Edison screw lamp holder is connected to the phase conductor
iii Ensure that phase neutral and earth conductors at socket outlets are connected at the correct
terminals
iv Test Equipment ndash Multimeter (Ohm range) or Ohm meter
v Test Method
1 1048766 Switch off Main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in Figure 85
5 1048766 Test switches and single phase control devices at the phase conductors
6 1048766 Test socket outlet connection sources
7 1048766 Test Edison screw lamp holder connections
8 1048766 Meter reading value shall be less than 1 Ω
Earth Electrode Resistance Test
i To test the earth electrode resistance
70 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
ii To ascertain the suitability of the location of the electrode
iii To ensure that the electrode is not buried within the resistance area of another electrode
iv Test equipment ndash Earth Resistance Tester
v Test method -
1 1048766 Terminal rsquoErsquo is connected to the electrode to be tested (green conductor)
2 1048766 Terminal lsquoPrsquo is connected to the potential spike (yellow conductor) at a distance of 10
meters from the earth electrode
3 1048766 Terminal lsquoCrsquo is connected to the current spike (red conductor) at a distance of 20 meters
from the earth electrode E P C Electrode 10 meter 10 meter
Figure 86 ndash Earth Electrode Resistance Measurement Test Equipment
Earth Electrode Resistance Measurement Method (Figure 86)
This test must be repeated at least three times to ensure that the reading is not affected by interacting
earthing regions
i Record the first reading (Z1) Example Z1 = 10 Ω
ii Move the voltage spike to a distance of 6 meters from the original position Record the second
reading (Z2) Example Z2 = 10 Ω
iii Move the voltage spike to a distance of 6 meters from the original position Record the third
reading (Z3)
Example Z3 = 10 Ω
Residual Current Device Test
71 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
i Ensure that the residual current device (RCD) trips within the set time on the occurrence of current
leakage to earth
ii Test Equipment ndash RCD Tester RCCB Tester
iii Test Method 1
1 1048766 Use the Trip Test Button
2 1048766 Press the trip button found on the RCD to determine if it trips or otherwise This test would
not be able to determine the sensitivity of the RCD nor the time taken for it to trip
iv Test Method 2
1048766 Use a RCD Tester
This equipment is equipped with a 13A plug which can be connected to a 13A socket outlet Select the
RCD sensitivity to be the same as the sensitivity of the RCD to be tested to determine if the RCD can
trip The time to trip shall not exceed 40 mS
1048766 Test method ndash
a) Position the selection switch in accordance with the sensitivity of the RCD used
Example 100 mA 01 A
b) Position the operations switch to lsquoNo Triprsquo (frac12 Rated mA = 50) connect the 3 pin plug to
the 13A socket outlet
c) Switch on the 13A socket outlet ndash ensure that the P-N and P-E lights light up This shows that
the polarity is correct (Note if both the lights as above do not light up the test cannot be
continued)
d) Press the test button ndash the reading shows less than 200 millisecond and simultaneously the
lsquotestrsquo light lights up and the P-N and P-E lights do not light up At that instant the RCD will
not trip
e) Move the selection switch to 180o (+ve wave) ndash repeat steps (d) and (e) = 100)
f) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
g) Move the selection switch to 0o (-ve wave)
h) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
i) The above test is repeated until a near correct reading is obtained
j) Record the test results
k) Change the operations switch to lsquoFast Triprsquo and press the test button ndash RCD will trip within a
time not exceeding 40 mS
l) Repeat a number of times at 0o or 180o
72 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 9 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (DC)
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
73 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Start stop button 240Vac 5A 2
9 Filament lamp (Bulb ) 240Vac 40W 3
10 Overload Relay 415V 20A 3
11 Three phase induction motor 5 hp 3
12 Single phase step down transformer 2500VA 1
13 Single core PVC insulated Cable 1mm 2 As required
14 Single core PVC insulated Cable 25mm 2 As required
15 DIN rail 35 mm As required
16 PVC type Cable tray 50 mm x 50 mm As required
17 Cable ties 4 ldquo As required
18 Flexible wires 05 mm As required
19 PVC Connectors 5 A amp 20 A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the schematic
diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a optional exercise
i Simple DOL starter
ii Forward reverse DOL starter
iii Forward Reverse Dahlander motor
iv Three motors operated in sequence by DOL starter operated by manual push
button or time delay relay
74 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
a One loop per-cycle
b Continuous operation in a loop
c optional circuit design to represent the same task
v Only one out of three motors to be operated at a time (quiz)
4 Test the functionality of completed project
LESSON 10 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (AC)
75 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 1
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Lamp point 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
76 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
11 Overload Relay 415V 20A 3
12 Three phase induction
motor
5 hp 3
13 Single core PVC insulated
Cable
1mm 2 As required
14 Single core PVC insulated
Cable
25mm 2 As required
15 DIN rail 35 mm As required
16 PVC type Cable tray 50 mm x 50 mm As required
17 Cable ties 4 ldquo As required
18 Flexible wires 05 mm As required
19 PVC Connectors 5 A amp 20 A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the
schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram optional exercise
4 Simple DOL starter
5 Forward reverse DOL starter
6 Test the functionality of completed project
77 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 1
78 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
cm
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Indicating light 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
11 Overload Relay 415V 20A 3
12 Three phase induction motor 5 hp 3
13 Single phase step down
transformer
2500VA 1
14 Single core PVC insulated
Cable
1mm 2 As required
15 Single core PVC insulated
Cable
25mm 2 As required
16 DIN rail 35 mm As required
17 PVC type Cable tray 50 mm x 50 mm As required
18 Cable ties 4 ldquo As required
19 Flexible wires 05 mm As required
20 PVC Connectors 5 A amp 20 A 240 V As required
21 Single pole MCB 6A 240 V 1
22 Single pole MCB 2A 240 V 1
23 Triple pole MCB 20A 415 V 1
24 Mounting board 30 cm x 40 cm x 3
cm
1
25 Relay cw 11 pin socket 10 A 240 Vac 2
26 Time delay relay 10 A 240 Vac 3
27 Triple pole Contactor 20A 240Vac 3
28 Batten type Lamp holder 240Vac 10 A 3
29 Start stop button 240Vac 10A 2
30 Indicating light (Bulb ) 240Vac 25W 3
31 Overload Relay 415V 20A 1
32 Three phase dahlander type
induction motor
5 hp 1
33 Single phase step down
transformer
24024Vac
2500VA
1
79 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
34 Single core PVC insulated
Cable
1mm 2 As required
35 Single core PVC insulated
Cable
25mm 2 As required
36 DIN rail 35 mm As required
37 PVC type Cable tray 50 mm x 50 mm As required
38 Cable ties 4 ldquo As required
39 Flexible wires 075 mm As required
40 PVC Connectors 5 A amp 20 A 240 V As required
41 Terminal block 20A 240Vac As required
Procedures
5 Identify each component according to specification and quantity required from the schematic
diagram attached
6 Test the functionality of each component by using multi-meter or power supply whichever
applicable
7 Wire component according to circuit diagram
8 Three motors operated in sequence by DOL starter operated by manual push button or time
delay relay
a One loop per-cycle
b Continuous operation in a loop
c optional circuit design to represent the same task
d Only one out of three motors to be operated at a time (quiz)
9 Test the functionality of completed project
80 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
BASIC DESIGN INDUSTRIAL MOTOR CONTROL (SEQUENCE CONTROL)
THREE PHASE INDUCTION MOTOR OPERATED IN SEQUENCE BY DIRECT ON LINE
STARTER
LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
81 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
82 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Lcd lamp indicator 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
11 Overload Relay 415V 20A 3
12 Three phase induction motor 5 hp 3
13 Single phase step down transformer 2500VA 1
14 Single core PVC insulated Cable 1mm 2 As required
15 Single core PVC insulated Cable 25mm 2 As required
16 DIN rail 35 mm As required
17 PVC type Cable tray 50 mm x 50 mm As required
18 Cable ties 4 ldquo As required
19 Flexible wires 1 mm Oslash As required
20 PVC Terminal block 10A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the schematic
diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a optional exercise
i Forward Reverse dahlander motor
4 Test the functionality of completed project
83 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
THREE PHASE DAHLANDER TYPE INDUCTION MOTOR OPERATED FORWARD AND
REVERSE OPERATION BY DIRECT ON LINE STARTER
84 ndash 99EASYTECH ENTERPRISE
LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
Introduction
If a motors windings are connected in the star configuration any two phases will be in series across
the supply and hence the line current will be smaller(by 577) than if the windings were connected in
the delta arrangement
Hence larger-type motors with heavy starting currents are first connected in star and then when the
starting currents fall in delta This of course means that all six of the ends of the windings must be
brought to terminations outside the casing (Fig 833)
EZTECH
EZTECH ELECTRICAL INSTALLATION GUIDE
The automatic version of this starter incorporates a timing relay which automatically changes the
connections from star to delta Figs 834 and 835 show the wiring and schematic diagrams for a star
delta starter
Objectives
1 Identify component and the specification
2 Design forward reverse star delta starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
2 ndash 99EASYTECH ENTERPRISE
REV -C
LEGENDMCCB Moulded Case Circuit BreakerTOR Thermal Over Load RelayFOW-C Mains Forward ContactorREV-C Mains Reverse ContactorDC Delta ContactorSC Star ContactorS-SW Mains Selector Switch
SC
V2
W2
U2
DC
V1
W1
U1
TOR
TOR
FOW-C
30A MCCB
TOR
MAIN CIRCUIT FORWARD REVERSE STAR DELTA
RYBN S
-SW
3 PHASEINDUCTION MOTOR
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Relay 10 A 240V 3
5 Triple pole Contactor
6 cw NO NC auxiliary contact
240Vac 20 A 4
7 Overload Relay 415 V 1
8 LED indicator 240vac 5 A 4
9 Start stop button 240Vac 5A 2
10 DIN rail 35 mm As required
11 Flexible wires 1 mm As required
12 Single core PVC insulated
wire
25 mm As required
13 Terminal block 20 A As required
14 Squirrel cage motor 5kW 1
15 5 pin plug and socket 415V 20A 1
16 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
3 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
a Manual star delta
b Manual Forward reverse star delta starter
c Automatic star delta starter
d Automatic Forward reverse star delta starter
4 Test the functionality of completed project
4 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
Objectives
1 Identify component and the specification
2 Design auto transformer starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
5 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Autotransformer starter is used to start a 3 phase induction motor that has a rating between 10 to 15 hp
6 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Autotransformer set 10Kw 415 V 50 Hz 1
5 Triple pole Contactor 240Vac 4
6 Batten type Lamp holder 240 Vac 105 A 4
7 Start stop button 240Vac 10A 4
8 Filament lamp (Bulb ) 240Vac 40W 4
9 DIN rail 35 mm As required
10 Flexible wires 1 mm As required
7 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
11 Single core PVC insulated
wire
25 mm As required
12 Terminal block 20 A As required
13 Squirrel cage motor 10kW 1
14 5 pin plug and socket 415V 20A 1
15 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a open transient autotransformer starter
b close transient autotransformer starter
c Forward reverse autotransformer starter
4 Test the functionality of completed project
8 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
Objectives
1 Identify component and the specification
2 Design rotor resistance starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
9 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Rotor Resistor set 10kW 1
5 Triple pole Contactor 240Vac 20A 4
6 Indicating light 240vac 5 A 4
7 Start stop push button 240Vac 5A 4
8 DIN rail 35 mm As required
9 Flexible wires 1 mm 2 As required
10 Single core PVC insulated wire 25 mm 2 As required
11 Terminal block 20 A As required
12 Slip Ring motor 10kW 1
13 5 pin round 3 phase socket 415V 20A 1
14 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
10 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
4 Test the functionality of completed project
a Dead circuit test b Life circuit test
5 Measure starting and running Amps
LESSON 16
TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
An installation in general will suffer damage
Damage usually occurs on the electric motor control as follows
1 Damage to the main circuit
2 Damage to the control circuit
The cause of the damage
i Overcurrent overload short circuit
ii Leakage current to ground
iii Equipment malfunction
iv The main control circuit
a Trip of main circuit protection devices fire
b Defect of motor terminal such as short circuit fire loose
v The control circuit is not functioning -
a contactor relay relay time overload relay does not work damaged burned
b Loose cable connection disconnected
Detecting and Repairing Damage
Examples of damage are as follows
i Motor does not work
ii Motor function and overload relay trips
iii Motor function but only partially functional control circuit
Methods of detecting damage
Among the known methods necessary to detect damage are as follows
1 Turn off the electricity at the main switch (main switch) in order to avoid any danger during the
work carried out to detect damage
2 Check all the protective gear that controls the motor control main circuit
11 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
3 Make sure the damage function control circuit
4 Check the control circuit according to the schematic circuit diagram of the motor control
5 Check the operation of the control circuit
Note
Use wiring that has been installed on the SYSTEM OF MOTOR CONTROL BOARD by Forward
Reverse control circuit for Star Delta to test and look for damage
SELF-ASSESSMENT QUESTIONS
1 (a) Explain what is meant by the term lsquoback emfrsquo in a motor
(b) Outline the basic differences between series shunt and compound wound dc motors
2 (a) With the aid of diagrams explain how the speed of series shunt and compound-wound motors
may be controlled
(b) A 440V dc shunt-wound motor has a field resistance of 200R and an armature resistance of 06 R
When its speed is 20 rev d second the current drawn from the supply is 122A Calculate its back
emf at this speed If the speed were decreased to 19 revssecond the field flux remaining unchanged
calculate the new back emf and the new armature current
3 A load of 64 kW at 240 V is supplied from the terminals of a shunt-wound dc generator The field
resistance is 180 A Calculate the armature current
4 (a) Explain with the aid of a diagram how a rotating magnetic field may be
(b) What is meant by lsquosynchronous speedrsquo
Calculate the synchronous obtained speed of a 12 pole motor if the supply frequency is 50Hz
5 (a) Explain the action of a synchronous motor
(b) What methods are available to start a synchronous motor Explain with diagrams
6 (a) Explain the action of a cage induction motor
(b) What is meant by the term lsquosliprsquo
Calculate the percentage slip of a six pole induction motor running at 162 revssecond from a 50 Hz
supply
7 Describe with sketches three different ways of starting a single-phase induction motor
12 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
8 Explain with the aid of a sketch the action of a three-phase DOL starter
What are dashpots used for How are remote start and stop buttons connected
9 A I0 kW 240V 50Hz single-phase cage rotor induction motor is 85efficient and has a PF of 068
lagging Calculate the motor current and the value of capacitor required to raise the PF to 093
lagging
10 Calculate the torque developed by an 18 kW four-pole induction motor run at 35 slip from a
50Hz supply
APPENDIX 1
13 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 11
14 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 111
Attachment Reference
httpswwwtlc-directcoukBook621htm
httpwwwstgovmyindexphpms
15 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
5 1048766 Test switches and single phase control devices at the phase conductors
6 1048766 Test socket outlet connection sources
7 1048766 Test Edison screw lamp holder connections
8 1048766 Meter reading value shall be less than 1 Ω
64 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Polarity test
65 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Earth Electrode Resistance Testi To test the earth electrode resistance
ii To ascertain the suitability of the location of the electrode
iii To ensure that the electrode is not buried within the resistance area of another electrode
iv Test equipment ndash Earth Resistance Tester
v Test method -
1 1048766 Terminal rsquoErsquo is connected to the electrode to be tested (green conductor)
2 1048766 Terminal lsquoPrsquo is connected to the potential spike (yellow conductor) at a distance of 10
meters from the earth electrode
3 1048766 Terminal lsquoCrsquo is connected to the current spike (red conductor) at a distance of 20 meters
from the earth electrode
Earth Electrode Resistance Measurement Method (Figure 86)
This test must be repeated at least three times to ensure that the reading is not affected by interacting
earthing regions
i Record the first reading (Z1) Example Z1 = 10 Ω
ii Move the voltage spike to a distance of 6 meters from the original position Record the second
reading (Z2 ) Example Z2 = 10 Ω
iii Move the voltage spike to a distance of 6 meters from the original position Record the third
reading (Z3) Example Z3 = 10 Ω
66 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Residual Current Device Testi Ensure that the residual current device (RCD) trips within the set time on the occurrence of current
leakage to earth
ii Test Equipment ndash RCD Tester RCCB Tester
iii Test Method 1
1 1048766 Use the Trip Test Button
2 1048766 Press the trip button found on the RCD to determine if it trips or otherwise This test would
not be able to determine the sensitivity of the RCD nor the time taken for it to trip
iv Test Method 2
i 1048766 Use a RCD Tester
ii This equipment is equipped with a 13A plug which can be connected to a 13A socket outlet
Select the RCD sensitivity to be the same as the sensitivity of the RCD to be tested to
determine if the RCD can trip The time to trip shall not exceed 40 mS
iii 1048766 Test method ndash
a) Position the selection switch in accordance with the sensitivity of the RCD used
Example 100 mA 01 A
b) Position the operations switch to lsquoNo Triprsquo (frac12 Rated mA = 50) connect the 3 pin plug to
the 13A socket outlet
67 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
c) Switch on the 13A socket outlet ndash ensure that the P-N and P-E lights light up
This shows that the polarity is correct (Note if both the lights as above do not light up the test cannot
be continued)
d) Press the test button ndash the reading shows less than 200 mS and simultaneously the lsquotestrsquo light lights
up and the P-N and P-E lights do not light up At that instant the RCD will not trip
e) Move the selection switch to 180o (+ve wave) ndash repeat steps (d) and (e) Move the operations
switch to lsquoTriprsquo (Rated mA = 100)
g) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200mS
h) Move the selection switch to 0o (-ve wave)
i) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
j) The above test is repeated until a near correct reading is obtained
k) Record the test results
l) Change the operations switch to lsquoFast Triprsquo and press the test button ndash RCD will trip within a
time not exceeding 40 millisecond
m) Repeat a number of times at 0o or 180o
On completion of a wiring installation a number of tests on the installation have to be conducted to
ascertain that the wiring circuits and connected appliances are safe for use Prior to carrying out the
tests an inspection has to be done the following tests shall be conducted
i Continuity Test
ii Insulation Resistance Test
iii Polarity Test
iv Earth Electrode Resistance test and
v Residual Current Device Test
821 Continuity Test
There are 3 main types of continuity tests for the final circuits-
i Protection Conductor Continuity Test
ii Final Ring Circuit Conductor Continuity Test
68 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
iii Live and Neutral Conductor Continuity Test
a) Protection Conductor Continuity Test
bull To ascertain that all protection conductors are connected in the correct and effective manner
bull Test equipment ndash Multimeter (Ohm range) or Ohm meter
bull Test Method
1 1048766 Ensure that the main switch RCD and MCB are open circuited (switched off) and all loads are
disconnected
2 1048766 Connected the test leads as in the Figure 81
3 1048766 The meter reading shall be less than 1 Ω
Final Ring Circuit Conductor Continuity Test
bull To ensure that all conductors around the ring circuit have continuity
bull Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
bull Test Method
1 1048766 Disconnect both the supply source live conductors from the MCB the neutral conductor
from the neutral terminals and the earth conductor from the earth terminal in the distribution
fuse box
2 1048766 Connect the test leads as in the Figure 82 (EE)
3 1048766 Repeat the procedure for (L-L) and (N-N)
4 1048766 The meter reading value shall be less than 1 ohm Figure 82 - Final Ring Circuit Conductor
Continuity Test Ohm Meter
Disconnect both the supply source cables from mcbfuse
Take readings at earth conductors of both sources and note resistance readings
Live and Neutral Conductor Continuity Test
1 To ensure that each conductor in the circuit has continuity
2 Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
3 Test Method
1 1048766 Switch off the Main switch RCD and MCB
2 1048766 Disconnect all loads
3 1048766 Switch on all switches in the circuit
4 1048766 Disconnect the fusesfinal circuit breakers and close the circuit
5 1048766 Carry out the test as shown in Figure 83
6 1048766 The meter reading value shall be less than 1 ohm Figure 83 - Live and Neutral
Conductor Continuity Test Ohm Meter
Insulation Resistance Test
69 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
i Ensure that there is no leakage current between phase conductors phase and neutral conductors and
phase conductor and earth
ii Test the strength of the cable insulation
iii Test Equipment ndash Insulation Resistance Tester Operating voltage is 250VDC or 500VDC
iv Test Method
1 1048766 Switch off main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in the Table below
5 1048766 Meter reading value shall be less than 1 Megaohm
Polarity Test
i Ensure that each fuse or single pole control and protection device is connected only in the phase
conductor
ii Intermediate contact of Edison screw lamp holder is connected to the phase conductor
iii Ensure that phase neutral and earth conductors at socket outlets are connected at the correct
terminals
iv Test Equipment ndash Multimeter (Ohm range) or Ohm meter
v Test Method
1 1048766 Switch off Main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in Figure 85
5 1048766 Test switches and single phase control devices at the phase conductors
6 1048766 Test socket outlet connection sources
7 1048766 Test Edison screw lamp holder connections
8 1048766 Meter reading value shall be less than 1 Ω
Earth Electrode Resistance Test
i To test the earth electrode resistance
70 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
ii To ascertain the suitability of the location of the electrode
iii To ensure that the electrode is not buried within the resistance area of another electrode
iv Test equipment ndash Earth Resistance Tester
v Test method -
1 1048766 Terminal rsquoErsquo is connected to the electrode to be tested (green conductor)
2 1048766 Terminal lsquoPrsquo is connected to the potential spike (yellow conductor) at a distance of 10
meters from the earth electrode
3 1048766 Terminal lsquoCrsquo is connected to the current spike (red conductor) at a distance of 20 meters
from the earth electrode E P C Electrode 10 meter 10 meter
Figure 86 ndash Earth Electrode Resistance Measurement Test Equipment
Earth Electrode Resistance Measurement Method (Figure 86)
This test must be repeated at least three times to ensure that the reading is not affected by interacting
earthing regions
i Record the first reading (Z1) Example Z1 = 10 Ω
ii Move the voltage spike to a distance of 6 meters from the original position Record the second
reading (Z2) Example Z2 = 10 Ω
iii Move the voltage spike to a distance of 6 meters from the original position Record the third
reading (Z3)
Example Z3 = 10 Ω
Residual Current Device Test
71 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
i Ensure that the residual current device (RCD) trips within the set time on the occurrence of current
leakage to earth
ii Test Equipment ndash RCD Tester RCCB Tester
iii Test Method 1
1 1048766 Use the Trip Test Button
2 1048766 Press the trip button found on the RCD to determine if it trips or otherwise This test would
not be able to determine the sensitivity of the RCD nor the time taken for it to trip
iv Test Method 2
1048766 Use a RCD Tester
This equipment is equipped with a 13A plug which can be connected to a 13A socket outlet Select the
RCD sensitivity to be the same as the sensitivity of the RCD to be tested to determine if the RCD can
trip The time to trip shall not exceed 40 mS
1048766 Test method ndash
a) Position the selection switch in accordance with the sensitivity of the RCD used
Example 100 mA 01 A
b) Position the operations switch to lsquoNo Triprsquo (frac12 Rated mA = 50) connect the 3 pin plug to
the 13A socket outlet
c) Switch on the 13A socket outlet ndash ensure that the P-N and P-E lights light up This shows that
the polarity is correct (Note if both the lights as above do not light up the test cannot be
continued)
d) Press the test button ndash the reading shows less than 200 millisecond and simultaneously the
lsquotestrsquo light lights up and the P-N and P-E lights do not light up At that instant the RCD will
not trip
e) Move the selection switch to 180o (+ve wave) ndash repeat steps (d) and (e) = 100)
f) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
g) Move the selection switch to 0o (-ve wave)
h) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
i) The above test is repeated until a near correct reading is obtained
j) Record the test results
k) Change the operations switch to lsquoFast Triprsquo and press the test button ndash RCD will trip within a
time not exceeding 40 mS
l) Repeat a number of times at 0o or 180o
72 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 9 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (DC)
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
73 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Start stop button 240Vac 5A 2
9 Filament lamp (Bulb ) 240Vac 40W 3
10 Overload Relay 415V 20A 3
11 Three phase induction motor 5 hp 3
12 Single phase step down transformer 2500VA 1
13 Single core PVC insulated Cable 1mm 2 As required
14 Single core PVC insulated Cable 25mm 2 As required
15 DIN rail 35 mm As required
16 PVC type Cable tray 50 mm x 50 mm As required
17 Cable ties 4 ldquo As required
18 Flexible wires 05 mm As required
19 PVC Connectors 5 A amp 20 A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the schematic
diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a optional exercise
i Simple DOL starter
ii Forward reverse DOL starter
iii Forward Reverse Dahlander motor
iv Three motors operated in sequence by DOL starter operated by manual push
button or time delay relay
74 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
a One loop per-cycle
b Continuous operation in a loop
c optional circuit design to represent the same task
v Only one out of three motors to be operated at a time (quiz)
4 Test the functionality of completed project
LESSON 10 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (AC)
75 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 1
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Lamp point 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
76 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
11 Overload Relay 415V 20A 3
12 Three phase induction
motor
5 hp 3
13 Single core PVC insulated
Cable
1mm 2 As required
14 Single core PVC insulated
Cable
25mm 2 As required
15 DIN rail 35 mm As required
16 PVC type Cable tray 50 mm x 50 mm As required
17 Cable ties 4 ldquo As required
18 Flexible wires 05 mm As required
19 PVC Connectors 5 A amp 20 A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the
schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram optional exercise
4 Simple DOL starter
5 Forward reverse DOL starter
6 Test the functionality of completed project
77 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 1
78 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
cm
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Indicating light 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
11 Overload Relay 415V 20A 3
12 Three phase induction motor 5 hp 3
13 Single phase step down
transformer
2500VA 1
14 Single core PVC insulated
Cable
1mm 2 As required
15 Single core PVC insulated
Cable
25mm 2 As required
16 DIN rail 35 mm As required
17 PVC type Cable tray 50 mm x 50 mm As required
18 Cable ties 4 ldquo As required
19 Flexible wires 05 mm As required
20 PVC Connectors 5 A amp 20 A 240 V As required
21 Single pole MCB 6A 240 V 1
22 Single pole MCB 2A 240 V 1
23 Triple pole MCB 20A 415 V 1
24 Mounting board 30 cm x 40 cm x 3
cm
1
25 Relay cw 11 pin socket 10 A 240 Vac 2
26 Time delay relay 10 A 240 Vac 3
27 Triple pole Contactor 20A 240Vac 3
28 Batten type Lamp holder 240Vac 10 A 3
29 Start stop button 240Vac 10A 2
30 Indicating light (Bulb ) 240Vac 25W 3
31 Overload Relay 415V 20A 1
32 Three phase dahlander type
induction motor
5 hp 1
33 Single phase step down
transformer
24024Vac
2500VA
1
79 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
34 Single core PVC insulated
Cable
1mm 2 As required
35 Single core PVC insulated
Cable
25mm 2 As required
36 DIN rail 35 mm As required
37 PVC type Cable tray 50 mm x 50 mm As required
38 Cable ties 4 ldquo As required
39 Flexible wires 075 mm As required
40 PVC Connectors 5 A amp 20 A 240 V As required
41 Terminal block 20A 240Vac As required
Procedures
5 Identify each component according to specification and quantity required from the schematic
diagram attached
6 Test the functionality of each component by using multi-meter or power supply whichever
applicable
7 Wire component according to circuit diagram
8 Three motors operated in sequence by DOL starter operated by manual push button or time
delay relay
a One loop per-cycle
b Continuous operation in a loop
c optional circuit design to represent the same task
d Only one out of three motors to be operated at a time (quiz)
9 Test the functionality of completed project
80 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
BASIC DESIGN INDUSTRIAL MOTOR CONTROL (SEQUENCE CONTROL)
THREE PHASE INDUCTION MOTOR OPERATED IN SEQUENCE BY DIRECT ON LINE
STARTER
LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
81 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
82 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Lcd lamp indicator 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
11 Overload Relay 415V 20A 3
12 Three phase induction motor 5 hp 3
13 Single phase step down transformer 2500VA 1
14 Single core PVC insulated Cable 1mm 2 As required
15 Single core PVC insulated Cable 25mm 2 As required
16 DIN rail 35 mm As required
17 PVC type Cable tray 50 mm x 50 mm As required
18 Cable ties 4 ldquo As required
19 Flexible wires 1 mm Oslash As required
20 PVC Terminal block 10A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the schematic
diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a optional exercise
i Forward Reverse dahlander motor
4 Test the functionality of completed project
83 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
THREE PHASE DAHLANDER TYPE INDUCTION MOTOR OPERATED FORWARD AND
REVERSE OPERATION BY DIRECT ON LINE STARTER
84 ndash 99EASYTECH ENTERPRISE
LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
Introduction
If a motors windings are connected in the star configuration any two phases will be in series across
the supply and hence the line current will be smaller(by 577) than if the windings were connected in
the delta arrangement
Hence larger-type motors with heavy starting currents are first connected in star and then when the
starting currents fall in delta This of course means that all six of the ends of the windings must be
brought to terminations outside the casing (Fig 833)
EZTECH
EZTECH ELECTRICAL INSTALLATION GUIDE
The automatic version of this starter incorporates a timing relay which automatically changes the
connections from star to delta Figs 834 and 835 show the wiring and schematic diagrams for a star
delta starter
Objectives
1 Identify component and the specification
2 Design forward reverse star delta starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
2 ndash 99EASYTECH ENTERPRISE
REV -C
LEGENDMCCB Moulded Case Circuit BreakerTOR Thermal Over Load RelayFOW-C Mains Forward ContactorREV-C Mains Reverse ContactorDC Delta ContactorSC Star ContactorS-SW Mains Selector Switch
SC
V2
W2
U2
DC
V1
W1
U1
TOR
TOR
FOW-C
30A MCCB
TOR
MAIN CIRCUIT FORWARD REVERSE STAR DELTA
RYBN S
-SW
3 PHASEINDUCTION MOTOR
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Relay 10 A 240V 3
5 Triple pole Contactor
6 cw NO NC auxiliary contact
240Vac 20 A 4
7 Overload Relay 415 V 1
8 LED indicator 240vac 5 A 4
9 Start stop button 240Vac 5A 2
10 DIN rail 35 mm As required
11 Flexible wires 1 mm As required
12 Single core PVC insulated
wire
25 mm As required
13 Terminal block 20 A As required
14 Squirrel cage motor 5kW 1
15 5 pin plug and socket 415V 20A 1
16 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
3 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
a Manual star delta
b Manual Forward reverse star delta starter
c Automatic star delta starter
d Automatic Forward reverse star delta starter
4 Test the functionality of completed project
4 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
Objectives
1 Identify component and the specification
2 Design auto transformer starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
5 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Autotransformer starter is used to start a 3 phase induction motor that has a rating between 10 to 15 hp
6 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Autotransformer set 10Kw 415 V 50 Hz 1
5 Triple pole Contactor 240Vac 4
6 Batten type Lamp holder 240 Vac 105 A 4
7 Start stop button 240Vac 10A 4
8 Filament lamp (Bulb ) 240Vac 40W 4
9 DIN rail 35 mm As required
10 Flexible wires 1 mm As required
7 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
11 Single core PVC insulated
wire
25 mm As required
12 Terminal block 20 A As required
13 Squirrel cage motor 10kW 1
14 5 pin plug and socket 415V 20A 1
15 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a open transient autotransformer starter
b close transient autotransformer starter
c Forward reverse autotransformer starter
4 Test the functionality of completed project
8 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
Objectives
1 Identify component and the specification
2 Design rotor resistance starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
9 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Rotor Resistor set 10kW 1
5 Triple pole Contactor 240Vac 20A 4
6 Indicating light 240vac 5 A 4
7 Start stop push button 240Vac 5A 4
8 DIN rail 35 mm As required
9 Flexible wires 1 mm 2 As required
10 Single core PVC insulated wire 25 mm 2 As required
11 Terminal block 20 A As required
12 Slip Ring motor 10kW 1
13 5 pin round 3 phase socket 415V 20A 1
14 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
10 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
4 Test the functionality of completed project
a Dead circuit test b Life circuit test
5 Measure starting and running Amps
LESSON 16
TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
An installation in general will suffer damage
Damage usually occurs on the electric motor control as follows
1 Damage to the main circuit
2 Damage to the control circuit
The cause of the damage
i Overcurrent overload short circuit
ii Leakage current to ground
iii Equipment malfunction
iv The main control circuit
a Trip of main circuit protection devices fire
b Defect of motor terminal such as short circuit fire loose
v The control circuit is not functioning -
a contactor relay relay time overload relay does not work damaged burned
b Loose cable connection disconnected
Detecting and Repairing Damage
Examples of damage are as follows
i Motor does not work
ii Motor function and overload relay trips
iii Motor function but only partially functional control circuit
Methods of detecting damage
Among the known methods necessary to detect damage are as follows
1 Turn off the electricity at the main switch (main switch) in order to avoid any danger during the
work carried out to detect damage
2 Check all the protective gear that controls the motor control main circuit
11 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
3 Make sure the damage function control circuit
4 Check the control circuit according to the schematic circuit diagram of the motor control
5 Check the operation of the control circuit
Note
Use wiring that has been installed on the SYSTEM OF MOTOR CONTROL BOARD by Forward
Reverse control circuit for Star Delta to test and look for damage
SELF-ASSESSMENT QUESTIONS
1 (a) Explain what is meant by the term lsquoback emfrsquo in a motor
(b) Outline the basic differences between series shunt and compound wound dc motors
2 (a) With the aid of diagrams explain how the speed of series shunt and compound-wound motors
may be controlled
(b) A 440V dc shunt-wound motor has a field resistance of 200R and an armature resistance of 06 R
When its speed is 20 rev d second the current drawn from the supply is 122A Calculate its back
emf at this speed If the speed were decreased to 19 revssecond the field flux remaining unchanged
calculate the new back emf and the new armature current
3 A load of 64 kW at 240 V is supplied from the terminals of a shunt-wound dc generator The field
resistance is 180 A Calculate the armature current
4 (a) Explain with the aid of a diagram how a rotating magnetic field may be
(b) What is meant by lsquosynchronous speedrsquo
Calculate the synchronous obtained speed of a 12 pole motor if the supply frequency is 50Hz
5 (a) Explain the action of a synchronous motor
(b) What methods are available to start a synchronous motor Explain with diagrams
6 (a) Explain the action of a cage induction motor
(b) What is meant by the term lsquosliprsquo
Calculate the percentage slip of a six pole induction motor running at 162 revssecond from a 50 Hz
supply
7 Describe with sketches three different ways of starting a single-phase induction motor
12 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
8 Explain with the aid of a sketch the action of a three-phase DOL starter
What are dashpots used for How are remote start and stop buttons connected
9 A I0 kW 240V 50Hz single-phase cage rotor induction motor is 85efficient and has a PF of 068
lagging Calculate the motor current and the value of capacitor required to raise the PF to 093
lagging
10 Calculate the torque developed by an 18 kW four-pole induction motor run at 35 slip from a
50Hz supply
APPENDIX 1
13 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 11
14 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 111
Attachment Reference
httpswwwtlc-directcoukBook621htm
httpwwwstgovmyindexphpms
15 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Polarity test
65 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Earth Electrode Resistance Testi To test the earth electrode resistance
ii To ascertain the suitability of the location of the electrode
iii To ensure that the electrode is not buried within the resistance area of another electrode
iv Test equipment ndash Earth Resistance Tester
v Test method -
1 1048766 Terminal rsquoErsquo is connected to the electrode to be tested (green conductor)
2 1048766 Terminal lsquoPrsquo is connected to the potential spike (yellow conductor) at a distance of 10
meters from the earth electrode
3 1048766 Terminal lsquoCrsquo is connected to the current spike (red conductor) at a distance of 20 meters
from the earth electrode
Earth Electrode Resistance Measurement Method (Figure 86)
This test must be repeated at least three times to ensure that the reading is not affected by interacting
earthing regions
i Record the first reading (Z1) Example Z1 = 10 Ω
ii Move the voltage spike to a distance of 6 meters from the original position Record the second
reading (Z2 ) Example Z2 = 10 Ω
iii Move the voltage spike to a distance of 6 meters from the original position Record the third
reading (Z3) Example Z3 = 10 Ω
66 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Residual Current Device Testi Ensure that the residual current device (RCD) trips within the set time on the occurrence of current
leakage to earth
ii Test Equipment ndash RCD Tester RCCB Tester
iii Test Method 1
1 1048766 Use the Trip Test Button
2 1048766 Press the trip button found on the RCD to determine if it trips or otherwise This test would
not be able to determine the sensitivity of the RCD nor the time taken for it to trip
iv Test Method 2
i 1048766 Use a RCD Tester
ii This equipment is equipped with a 13A plug which can be connected to a 13A socket outlet
Select the RCD sensitivity to be the same as the sensitivity of the RCD to be tested to
determine if the RCD can trip The time to trip shall not exceed 40 mS
iii 1048766 Test method ndash
a) Position the selection switch in accordance with the sensitivity of the RCD used
Example 100 mA 01 A
b) Position the operations switch to lsquoNo Triprsquo (frac12 Rated mA = 50) connect the 3 pin plug to
the 13A socket outlet
67 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
c) Switch on the 13A socket outlet ndash ensure that the P-N and P-E lights light up
This shows that the polarity is correct (Note if both the lights as above do not light up the test cannot
be continued)
d) Press the test button ndash the reading shows less than 200 mS and simultaneously the lsquotestrsquo light lights
up and the P-N and P-E lights do not light up At that instant the RCD will not trip
e) Move the selection switch to 180o (+ve wave) ndash repeat steps (d) and (e) Move the operations
switch to lsquoTriprsquo (Rated mA = 100)
g) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200mS
h) Move the selection switch to 0o (-ve wave)
i) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
j) The above test is repeated until a near correct reading is obtained
k) Record the test results
l) Change the operations switch to lsquoFast Triprsquo and press the test button ndash RCD will trip within a
time not exceeding 40 millisecond
m) Repeat a number of times at 0o or 180o
On completion of a wiring installation a number of tests on the installation have to be conducted to
ascertain that the wiring circuits and connected appliances are safe for use Prior to carrying out the
tests an inspection has to be done the following tests shall be conducted
i Continuity Test
ii Insulation Resistance Test
iii Polarity Test
iv Earth Electrode Resistance test and
v Residual Current Device Test
821 Continuity Test
There are 3 main types of continuity tests for the final circuits-
i Protection Conductor Continuity Test
ii Final Ring Circuit Conductor Continuity Test
68 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
iii Live and Neutral Conductor Continuity Test
a) Protection Conductor Continuity Test
bull To ascertain that all protection conductors are connected in the correct and effective manner
bull Test equipment ndash Multimeter (Ohm range) or Ohm meter
bull Test Method
1 1048766 Ensure that the main switch RCD and MCB are open circuited (switched off) and all loads are
disconnected
2 1048766 Connected the test leads as in the Figure 81
3 1048766 The meter reading shall be less than 1 Ω
Final Ring Circuit Conductor Continuity Test
bull To ensure that all conductors around the ring circuit have continuity
bull Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
bull Test Method
1 1048766 Disconnect both the supply source live conductors from the MCB the neutral conductor
from the neutral terminals and the earth conductor from the earth terminal in the distribution
fuse box
2 1048766 Connect the test leads as in the Figure 82 (EE)
3 1048766 Repeat the procedure for (L-L) and (N-N)
4 1048766 The meter reading value shall be less than 1 ohm Figure 82 - Final Ring Circuit Conductor
Continuity Test Ohm Meter
Disconnect both the supply source cables from mcbfuse
Take readings at earth conductors of both sources and note resistance readings
Live and Neutral Conductor Continuity Test
1 To ensure that each conductor in the circuit has continuity
2 Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
3 Test Method
1 1048766 Switch off the Main switch RCD and MCB
2 1048766 Disconnect all loads
3 1048766 Switch on all switches in the circuit
4 1048766 Disconnect the fusesfinal circuit breakers and close the circuit
5 1048766 Carry out the test as shown in Figure 83
6 1048766 The meter reading value shall be less than 1 ohm Figure 83 - Live and Neutral
Conductor Continuity Test Ohm Meter
Insulation Resistance Test
69 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
i Ensure that there is no leakage current between phase conductors phase and neutral conductors and
phase conductor and earth
ii Test the strength of the cable insulation
iii Test Equipment ndash Insulation Resistance Tester Operating voltage is 250VDC or 500VDC
iv Test Method
1 1048766 Switch off main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in the Table below
5 1048766 Meter reading value shall be less than 1 Megaohm
Polarity Test
i Ensure that each fuse or single pole control and protection device is connected only in the phase
conductor
ii Intermediate contact of Edison screw lamp holder is connected to the phase conductor
iii Ensure that phase neutral and earth conductors at socket outlets are connected at the correct
terminals
iv Test Equipment ndash Multimeter (Ohm range) or Ohm meter
v Test Method
1 1048766 Switch off Main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in Figure 85
5 1048766 Test switches and single phase control devices at the phase conductors
6 1048766 Test socket outlet connection sources
7 1048766 Test Edison screw lamp holder connections
8 1048766 Meter reading value shall be less than 1 Ω
Earth Electrode Resistance Test
i To test the earth electrode resistance
70 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
ii To ascertain the suitability of the location of the electrode
iii To ensure that the electrode is not buried within the resistance area of another electrode
iv Test equipment ndash Earth Resistance Tester
v Test method -
1 1048766 Terminal rsquoErsquo is connected to the electrode to be tested (green conductor)
2 1048766 Terminal lsquoPrsquo is connected to the potential spike (yellow conductor) at a distance of 10
meters from the earth electrode
3 1048766 Terminal lsquoCrsquo is connected to the current spike (red conductor) at a distance of 20 meters
from the earth electrode E P C Electrode 10 meter 10 meter
Figure 86 ndash Earth Electrode Resistance Measurement Test Equipment
Earth Electrode Resistance Measurement Method (Figure 86)
This test must be repeated at least three times to ensure that the reading is not affected by interacting
earthing regions
i Record the first reading (Z1) Example Z1 = 10 Ω
ii Move the voltage spike to a distance of 6 meters from the original position Record the second
reading (Z2) Example Z2 = 10 Ω
iii Move the voltage spike to a distance of 6 meters from the original position Record the third
reading (Z3)
Example Z3 = 10 Ω
Residual Current Device Test
71 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
i Ensure that the residual current device (RCD) trips within the set time on the occurrence of current
leakage to earth
ii Test Equipment ndash RCD Tester RCCB Tester
iii Test Method 1
1 1048766 Use the Trip Test Button
2 1048766 Press the trip button found on the RCD to determine if it trips or otherwise This test would
not be able to determine the sensitivity of the RCD nor the time taken for it to trip
iv Test Method 2
1048766 Use a RCD Tester
This equipment is equipped with a 13A plug which can be connected to a 13A socket outlet Select the
RCD sensitivity to be the same as the sensitivity of the RCD to be tested to determine if the RCD can
trip The time to trip shall not exceed 40 mS
1048766 Test method ndash
a) Position the selection switch in accordance with the sensitivity of the RCD used
Example 100 mA 01 A
b) Position the operations switch to lsquoNo Triprsquo (frac12 Rated mA = 50) connect the 3 pin plug to
the 13A socket outlet
c) Switch on the 13A socket outlet ndash ensure that the P-N and P-E lights light up This shows that
the polarity is correct (Note if both the lights as above do not light up the test cannot be
continued)
d) Press the test button ndash the reading shows less than 200 millisecond and simultaneously the
lsquotestrsquo light lights up and the P-N and P-E lights do not light up At that instant the RCD will
not trip
e) Move the selection switch to 180o (+ve wave) ndash repeat steps (d) and (e) = 100)
f) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
g) Move the selection switch to 0o (-ve wave)
h) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
i) The above test is repeated until a near correct reading is obtained
j) Record the test results
k) Change the operations switch to lsquoFast Triprsquo and press the test button ndash RCD will trip within a
time not exceeding 40 mS
l) Repeat a number of times at 0o or 180o
72 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 9 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (DC)
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
73 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Start stop button 240Vac 5A 2
9 Filament lamp (Bulb ) 240Vac 40W 3
10 Overload Relay 415V 20A 3
11 Three phase induction motor 5 hp 3
12 Single phase step down transformer 2500VA 1
13 Single core PVC insulated Cable 1mm 2 As required
14 Single core PVC insulated Cable 25mm 2 As required
15 DIN rail 35 mm As required
16 PVC type Cable tray 50 mm x 50 mm As required
17 Cable ties 4 ldquo As required
18 Flexible wires 05 mm As required
19 PVC Connectors 5 A amp 20 A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the schematic
diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a optional exercise
i Simple DOL starter
ii Forward reverse DOL starter
iii Forward Reverse Dahlander motor
iv Three motors operated in sequence by DOL starter operated by manual push
button or time delay relay
74 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
a One loop per-cycle
b Continuous operation in a loop
c optional circuit design to represent the same task
v Only one out of three motors to be operated at a time (quiz)
4 Test the functionality of completed project
LESSON 10 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (AC)
75 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 1
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Lamp point 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
76 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
11 Overload Relay 415V 20A 3
12 Three phase induction
motor
5 hp 3
13 Single core PVC insulated
Cable
1mm 2 As required
14 Single core PVC insulated
Cable
25mm 2 As required
15 DIN rail 35 mm As required
16 PVC type Cable tray 50 mm x 50 mm As required
17 Cable ties 4 ldquo As required
18 Flexible wires 05 mm As required
19 PVC Connectors 5 A amp 20 A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the
schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram optional exercise
4 Simple DOL starter
5 Forward reverse DOL starter
6 Test the functionality of completed project
77 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 1
78 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
cm
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Indicating light 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
11 Overload Relay 415V 20A 3
12 Three phase induction motor 5 hp 3
13 Single phase step down
transformer
2500VA 1
14 Single core PVC insulated
Cable
1mm 2 As required
15 Single core PVC insulated
Cable
25mm 2 As required
16 DIN rail 35 mm As required
17 PVC type Cable tray 50 mm x 50 mm As required
18 Cable ties 4 ldquo As required
19 Flexible wires 05 mm As required
20 PVC Connectors 5 A amp 20 A 240 V As required
21 Single pole MCB 6A 240 V 1
22 Single pole MCB 2A 240 V 1
23 Triple pole MCB 20A 415 V 1
24 Mounting board 30 cm x 40 cm x 3
cm
1
25 Relay cw 11 pin socket 10 A 240 Vac 2
26 Time delay relay 10 A 240 Vac 3
27 Triple pole Contactor 20A 240Vac 3
28 Batten type Lamp holder 240Vac 10 A 3
29 Start stop button 240Vac 10A 2
30 Indicating light (Bulb ) 240Vac 25W 3
31 Overload Relay 415V 20A 1
32 Three phase dahlander type
induction motor
5 hp 1
33 Single phase step down
transformer
24024Vac
2500VA
1
79 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
34 Single core PVC insulated
Cable
1mm 2 As required
35 Single core PVC insulated
Cable
25mm 2 As required
36 DIN rail 35 mm As required
37 PVC type Cable tray 50 mm x 50 mm As required
38 Cable ties 4 ldquo As required
39 Flexible wires 075 mm As required
40 PVC Connectors 5 A amp 20 A 240 V As required
41 Terminal block 20A 240Vac As required
Procedures
5 Identify each component according to specification and quantity required from the schematic
diagram attached
6 Test the functionality of each component by using multi-meter or power supply whichever
applicable
7 Wire component according to circuit diagram
8 Three motors operated in sequence by DOL starter operated by manual push button or time
delay relay
a One loop per-cycle
b Continuous operation in a loop
c optional circuit design to represent the same task
d Only one out of three motors to be operated at a time (quiz)
9 Test the functionality of completed project
80 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
BASIC DESIGN INDUSTRIAL MOTOR CONTROL (SEQUENCE CONTROL)
THREE PHASE INDUCTION MOTOR OPERATED IN SEQUENCE BY DIRECT ON LINE
STARTER
LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
81 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
82 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Lcd lamp indicator 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
11 Overload Relay 415V 20A 3
12 Three phase induction motor 5 hp 3
13 Single phase step down transformer 2500VA 1
14 Single core PVC insulated Cable 1mm 2 As required
15 Single core PVC insulated Cable 25mm 2 As required
16 DIN rail 35 mm As required
17 PVC type Cable tray 50 mm x 50 mm As required
18 Cable ties 4 ldquo As required
19 Flexible wires 1 mm Oslash As required
20 PVC Terminal block 10A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the schematic
diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a optional exercise
i Forward Reverse dahlander motor
4 Test the functionality of completed project
83 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
THREE PHASE DAHLANDER TYPE INDUCTION MOTOR OPERATED FORWARD AND
REVERSE OPERATION BY DIRECT ON LINE STARTER
84 ndash 99EASYTECH ENTERPRISE
LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
Introduction
If a motors windings are connected in the star configuration any two phases will be in series across
the supply and hence the line current will be smaller(by 577) than if the windings were connected in
the delta arrangement
Hence larger-type motors with heavy starting currents are first connected in star and then when the
starting currents fall in delta This of course means that all six of the ends of the windings must be
brought to terminations outside the casing (Fig 833)
EZTECH
EZTECH ELECTRICAL INSTALLATION GUIDE
The automatic version of this starter incorporates a timing relay which automatically changes the
connections from star to delta Figs 834 and 835 show the wiring and schematic diagrams for a star
delta starter
Objectives
1 Identify component and the specification
2 Design forward reverse star delta starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
2 ndash 99EASYTECH ENTERPRISE
REV -C
LEGENDMCCB Moulded Case Circuit BreakerTOR Thermal Over Load RelayFOW-C Mains Forward ContactorREV-C Mains Reverse ContactorDC Delta ContactorSC Star ContactorS-SW Mains Selector Switch
SC
V2
W2
U2
DC
V1
W1
U1
TOR
TOR
FOW-C
30A MCCB
TOR
MAIN CIRCUIT FORWARD REVERSE STAR DELTA
RYBN S
-SW
3 PHASEINDUCTION MOTOR
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Relay 10 A 240V 3
5 Triple pole Contactor
6 cw NO NC auxiliary contact
240Vac 20 A 4
7 Overload Relay 415 V 1
8 LED indicator 240vac 5 A 4
9 Start stop button 240Vac 5A 2
10 DIN rail 35 mm As required
11 Flexible wires 1 mm As required
12 Single core PVC insulated
wire
25 mm As required
13 Terminal block 20 A As required
14 Squirrel cage motor 5kW 1
15 5 pin plug and socket 415V 20A 1
16 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
3 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
a Manual star delta
b Manual Forward reverse star delta starter
c Automatic star delta starter
d Automatic Forward reverse star delta starter
4 Test the functionality of completed project
4 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
Objectives
1 Identify component and the specification
2 Design auto transformer starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
5 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Autotransformer starter is used to start a 3 phase induction motor that has a rating between 10 to 15 hp
6 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Autotransformer set 10Kw 415 V 50 Hz 1
5 Triple pole Contactor 240Vac 4
6 Batten type Lamp holder 240 Vac 105 A 4
7 Start stop button 240Vac 10A 4
8 Filament lamp (Bulb ) 240Vac 40W 4
9 DIN rail 35 mm As required
10 Flexible wires 1 mm As required
7 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
11 Single core PVC insulated
wire
25 mm As required
12 Terminal block 20 A As required
13 Squirrel cage motor 10kW 1
14 5 pin plug and socket 415V 20A 1
15 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a open transient autotransformer starter
b close transient autotransformer starter
c Forward reverse autotransformer starter
4 Test the functionality of completed project
8 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
Objectives
1 Identify component and the specification
2 Design rotor resistance starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
9 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Rotor Resistor set 10kW 1
5 Triple pole Contactor 240Vac 20A 4
6 Indicating light 240vac 5 A 4
7 Start stop push button 240Vac 5A 4
8 DIN rail 35 mm As required
9 Flexible wires 1 mm 2 As required
10 Single core PVC insulated wire 25 mm 2 As required
11 Terminal block 20 A As required
12 Slip Ring motor 10kW 1
13 5 pin round 3 phase socket 415V 20A 1
14 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
10 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
4 Test the functionality of completed project
a Dead circuit test b Life circuit test
5 Measure starting and running Amps
LESSON 16
TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
An installation in general will suffer damage
Damage usually occurs on the electric motor control as follows
1 Damage to the main circuit
2 Damage to the control circuit
The cause of the damage
i Overcurrent overload short circuit
ii Leakage current to ground
iii Equipment malfunction
iv The main control circuit
a Trip of main circuit protection devices fire
b Defect of motor terminal such as short circuit fire loose
v The control circuit is not functioning -
a contactor relay relay time overload relay does not work damaged burned
b Loose cable connection disconnected
Detecting and Repairing Damage
Examples of damage are as follows
i Motor does not work
ii Motor function and overload relay trips
iii Motor function but only partially functional control circuit
Methods of detecting damage
Among the known methods necessary to detect damage are as follows
1 Turn off the electricity at the main switch (main switch) in order to avoid any danger during the
work carried out to detect damage
2 Check all the protective gear that controls the motor control main circuit
11 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
3 Make sure the damage function control circuit
4 Check the control circuit according to the schematic circuit diagram of the motor control
5 Check the operation of the control circuit
Note
Use wiring that has been installed on the SYSTEM OF MOTOR CONTROL BOARD by Forward
Reverse control circuit for Star Delta to test and look for damage
SELF-ASSESSMENT QUESTIONS
1 (a) Explain what is meant by the term lsquoback emfrsquo in a motor
(b) Outline the basic differences between series shunt and compound wound dc motors
2 (a) With the aid of diagrams explain how the speed of series shunt and compound-wound motors
may be controlled
(b) A 440V dc shunt-wound motor has a field resistance of 200R and an armature resistance of 06 R
When its speed is 20 rev d second the current drawn from the supply is 122A Calculate its back
emf at this speed If the speed were decreased to 19 revssecond the field flux remaining unchanged
calculate the new back emf and the new armature current
3 A load of 64 kW at 240 V is supplied from the terminals of a shunt-wound dc generator The field
resistance is 180 A Calculate the armature current
4 (a) Explain with the aid of a diagram how a rotating magnetic field may be
(b) What is meant by lsquosynchronous speedrsquo
Calculate the synchronous obtained speed of a 12 pole motor if the supply frequency is 50Hz
5 (a) Explain the action of a synchronous motor
(b) What methods are available to start a synchronous motor Explain with diagrams
6 (a) Explain the action of a cage induction motor
(b) What is meant by the term lsquosliprsquo
Calculate the percentage slip of a six pole induction motor running at 162 revssecond from a 50 Hz
supply
7 Describe with sketches three different ways of starting a single-phase induction motor
12 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
8 Explain with the aid of a sketch the action of a three-phase DOL starter
What are dashpots used for How are remote start and stop buttons connected
9 A I0 kW 240V 50Hz single-phase cage rotor induction motor is 85efficient and has a PF of 068
lagging Calculate the motor current and the value of capacitor required to raise the PF to 093
lagging
10 Calculate the torque developed by an 18 kW four-pole induction motor run at 35 slip from a
50Hz supply
APPENDIX 1
13 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 11
14 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 111
Attachment Reference
httpswwwtlc-directcoukBook621htm
httpwwwstgovmyindexphpms
15 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Earth Electrode Resistance Testi To test the earth electrode resistance
ii To ascertain the suitability of the location of the electrode
iii To ensure that the electrode is not buried within the resistance area of another electrode
iv Test equipment ndash Earth Resistance Tester
v Test method -
1 1048766 Terminal rsquoErsquo is connected to the electrode to be tested (green conductor)
2 1048766 Terminal lsquoPrsquo is connected to the potential spike (yellow conductor) at a distance of 10
meters from the earth electrode
3 1048766 Terminal lsquoCrsquo is connected to the current spike (red conductor) at a distance of 20 meters
from the earth electrode
Earth Electrode Resistance Measurement Method (Figure 86)
This test must be repeated at least three times to ensure that the reading is not affected by interacting
earthing regions
i Record the first reading (Z1) Example Z1 = 10 Ω
ii Move the voltage spike to a distance of 6 meters from the original position Record the second
reading (Z2 ) Example Z2 = 10 Ω
iii Move the voltage spike to a distance of 6 meters from the original position Record the third
reading (Z3) Example Z3 = 10 Ω
66 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Residual Current Device Testi Ensure that the residual current device (RCD) trips within the set time on the occurrence of current
leakage to earth
ii Test Equipment ndash RCD Tester RCCB Tester
iii Test Method 1
1 1048766 Use the Trip Test Button
2 1048766 Press the trip button found on the RCD to determine if it trips or otherwise This test would
not be able to determine the sensitivity of the RCD nor the time taken for it to trip
iv Test Method 2
i 1048766 Use a RCD Tester
ii This equipment is equipped with a 13A plug which can be connected to a 13A socket outlet
Select the RCD sensitivity to be the same as the sensitivity of the RCD to be tested to
determine if the RCD can trip The time to trip shall not exceed 40 mS
iii 1048766 Test method ndash
a) Position the selection switch in accordance with the sensitivity of the RCD used
Example 100 mA 01 A
b) Position the operations switch to lsquoNo Triprsquo (frac12 Rated mA = 50) connect the 3 pin plug to
the 13A socket outlet
67 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
c) Switch on the 13A socket outlet ndash ensure that the P-N and P-E lights light up
This shows that the polarity is correct (Note if both the lights as above do not light up the test cannot
be continued)
d) Press the test button ndash the reading shows less than 200 mS and simultaneously the lsquotestrsquo light lights
up and the P-N and P-E lights do not light up At that instant the RCD will not trip
e) Move the selection switch to 180o (+ve wave) ndash repeat steps (d) and (e) Move the operations
switch to lsquoTriprsquo (Rated mA = 100)
g) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200mS
h) Move the selection switch to 0o (-ve wave)
i) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
j) The above test is repeated until a near correct reading is obtained
k) Record the test results
l) Change the operations switch to lsquoFast Triprsquo and press the test button ndash RCD will trip within a
time not exceeding 40 millisecond
m) Repeat a number of times at 0o or 180o
On completion of a wiring installation a number of tests on the installation have to be conducted to
ascertain that the wiring circuits and connected appliances are safe for use Prior to carrying out the
tests an inspection has to be done the following tests shall be conducted
i Continuity Test
ii Insulation Resistance Test
iii Polarity Test
iv Earth Electrode Resistance test and
v Residual Current Device Test
821 Continuity Test
There are 3 main types of continuity tests for the final circuits-
i Protection Conductor Continuity Test
ii Final Ring Circuit Conductor Continuity Test
68 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
iii Live and Neutral Conductor Continuity Test
a) Protection Conductor Continuity Test
bull To ascertain that all protection conductors are connected in the correct and effective manner
bull Test equipment ndash Multimeter (Ohm range) or Ohm meter
bull Test Method
1 1048766 Ensure that the main switch RCD and MCB are open circuited (switched off) and all loads are
disconnected
2 1048766 Connected the test leads as in the Figure 81
3 1048766 The meter reading shall be less than 1 Ω
Final Ring Circuit Conductor Continuity Test
bull To ensure that all conductors around the ring circuit have continuity
bull Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
bull Test Method
1 1048766 Disconnect both the supply source live conductors from the MCB the neutral conductor
from the neutral terminals and the earth conductor from the earth terminal in the distribution
fuse box
2 1048766 Connect the test leads as in the Figure 82 (EE)
3 1048766 Repeat the procedure for (L-L) and (N-N)
4 1048766 The meter reading value shall be less than 1 ohm Figure 82 - Final Ring Circuit Conductor
Continuity Test Ohm Meter
Disconnect both the supply source cables from mcbfuse
Take readings at earth conductors of both sources and note resistance readings
Live and Neutral Conductor Continuity Test
1 To ensure that each conductor in the circuit has continuity
2 Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
3 Test Method
1 1048766 Switch off the Main switch RCD and MCB
2 1048766 Disconnect all loads
3 1048766 Switch on all switches in the circuit
4 1048766 Disconnect the fusesfinal circuit breakers and close the circuit
5 1048766 Carry out the test as shown in Figure 83
6 1048766 The meter reading value shall be less than 1 ohm Figure 83 - Live and Neutral
Conductor Continuity Test Ohm Meter
Insulation Resistance Test
69 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
i Ensure that there is no leakage current between phase conductors phase and neutral conductors and
phase conductor and earth
ii Test the strength of the cable insulation
iii Test Equipment ndash Insulation Resistance Tester Operating voltage is 250VDC or 500VDC
iv Test Method
1 1048766 Switch off main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in the Table below
5 1048766 Meter reading value shall be less than 1 Megaohm
Polarity Test
i Ensure that each fuse or single pole control and protection device is connected only in the phase
conductor
ii Intermediate contact of Edison screw lamp holder is connected to the phase conductor
iii Ensure that phase neutral and earth conductors at socket outlets are connected at the correct
terminals
iv Test Equipment ndash Multimeter (Ohm range) or Ohm meter
v Test Method
1 1048766 Switch off Main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in Figure 85
5 1048766 Test switches and single phase control devices at the phase conductors
6 1048766 Test socket outlet connection sources
7 1048766 Test Edison screw lamp holder connections
8 1048766 Meter reading value shall be less than 1 Ω
Earth Electrode Resistance Test
i To test the earth electrode resistance
70 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
ii To ascertain the suitability of the location of the electrode
iii To ensure that the electrode is not buried within the resistance area of another electrode
iv Test equipment ndash Earth Resistance Tester
v Test method -
1 1048766 Terminal rsquoErsquo is connected to the electrode to be tested (green conductor)
2 1048766 Terminal lsquoPrsquo is connected to the potential spike (yellow conductor) at a distance of 10
meters from the earth electrode
3 1048766 Terminal lsquoCrsquo is connected to the current spike (red conductor) at a distance of 20 meters
from the earth electrode E P C Electrode 10 meter 10 meter
Figure 86 ndash Earth Electrode Resistance Measurement Test Equipment
Earth Electrode Resistance Measurement Method (Figure 86)
This test must be repeated at least three times to ensure that the reading is not affected by interacting
earthing regions
i Record the first reading (Z1) Example Z1 = 10 Ω
ii Move the voltage spike to a distance of 6 meters from the original position Record the second
reading (Z2) Example Z2 = 10 Ω
iii Move the voltage spike to a distance of 6 meters from the original position Record the third
reading (Z3)
Example Z3 = 10 Ω
Residual Current Device Test
71 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
i Ensure that the residual current device (RCD) trips within the set time on the occurrence of current
leakage to earth
ii Test Equipment ndash RCD Tester RCCB Tester
iii Test Method 1
1 1048766 Use the Trip Test Button
2 1048766 Press the trip button found on the RCD to determine if it trips or otherwise This test would
not be able to determine the sensitivity of the RCD nor the time taken for it to trip
iv Test Method 2
1048766 Use a RCD Tester
This equipment is equipped with a 13A plug which can be connected to a 13A socket outlet Select the
RCD sensitivity to be the same as the sensitivity of the RCD to be tested to determine if the RCD can
trip The time to trip shall not exceed 40 mS
1048766 Test method ndash
a) Position the selection switch in accordance with the sensitivity of the RCD used
Example 100 mA 01 A
b) Position the operations switch to lsquoNo Triprsquo (frac12 Rated mA = 50) connect the 3 pin plug to
the 13A socket outlet
c) Switch on the 13A socket outlet ndash ensure that the P-N and P-E lights light up This shows that
the polarity is correct (Note if both the lights as above do not light up the test cannot be
continued)
d) Press the test button ndash the reading shows less than 200 millisecond and simultaneously the
lsquotestrsquo light lights up and the P-N and P-E lights do not light up At that instant the RCD will
not trip
e) Move the selection switch to 180o (+ve wave) ndash repeat steps (d) and (e) = 100)
f) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
g) Move the selection switch to 0o (-ve wave)
h) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
i) The above test is repeated until a near correct reading is obtained
j) Record the test results
k) Change the operations switch to lsquoFast Triprsquo and press the test button ndash RCD will trip within a
time not exceeding 40 mS
l) Repeat a number of times at 0o or 180o
72 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 9 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (DC)
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
73 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Start stop button 240Vac 5A 2
9 Filament lamp (Bulb ) 240Vac 40W 3
10 Overload Relay 415V 20A 3
11 Three phase induction motor 5 hp 3
12 Single phase step down transformer 2500VA 1
13 Single core PVC insulated Cable 1mm 2 As required
14 Single core PVC insulated Cable 25mm 2 As required
15 DIN rail 35 mm As required
16 PVC type Cable tray 50 mm x 50 mm As required
17 Cable ties 4 ldquo As required
18 Flexible wires 05 mm As required
19 PVC Connectors 5 A amp 20 A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the schematic
diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a optional exercise
i Simple DOL starter
ii Forward reverse DOL starter
iii Forward Reverse Dahlander motor
iv Three motors operated in sequence by DOL starter operated by manual push
button or time delay relay
74 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
a One loop per-cycle
b Continuous operation in a loop
c optional circuit design to represent the same task
v Only one out of three motors to be operated at a time (quiz)
4 Test the functionality of completed project
LESSON 10 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (AC)
75 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 1
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Lamp point 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
76 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
11 Overload Relay 415V 20A 3
12 Three phase induction
motor
5 hp 3
13 Single core PVC insulated
Cable
1mm 2 As required
14 Single core PVC insulated
Cable
25mm 2 As required
15 DIN rail 35 mm As required
16 PVC type Cable tray 50 mm x 50 mm As required
17 Cable ties 4 ldquo As required
18 Flexible wires 05 mm As required
19 PVC Connectors 5 A amp 20 A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the
schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram optional exercise
4 Simple DOL starter
5 Forward reverse DOL starter
6 Test the functionality of completed project
77 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 1
78 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
cm
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Indicating light 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
11 Overload Relay 415V 20A 3
12 Three phase induction motor 5 hp 3
13 Single phase step down
transformer
2500VA 1
14 Single core PVC insulated
Cable
1mm 2 As required
15 Single core PVC insulated
Cable
25mm 2 As required
16 DIN rail 35 mm As required
17 PVC type Cable tray 50 mm x 50 mm As required
18 Cable ties 4 ldquo As required
19 Flexible wires 05 mm As required
20 PVC Connectors 5 A amp 20 A 240 V As required
21 Single pole MCB 6A 240 V 1
22 Single pole MCB 2A 240 V 1
23 Triple pole MCB 20A 415 V 1
24 Mounting board 30 cm x 40 cm x 3
cm
1
25 Relay cw 11 pin socket 10 A 240 Vac 2
26 Time delay relay 10 A 240 Vac 3
27 Triple pole Contactor 20A 240Vac 3
28 Batten type Lamp holder 240Vac 10 A 3
29 Start stop button 240Vac 10A 2
30 Indicating light (Bulb ) 240Vac 25W 3
31 Overload Relay 415V 20A 1
32 Three phase dahlander type
induction motor
5 hp 1
33 Single phase step down
transformer
24024Vac
2500VA
1
79 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
34 Single core PVC insulated
Cable
1mm 2 As required
35 Single core PVC insulated
Cable
25mm 2 As required
36 DIN rail 35 mm As required
37 PVC type Cable tray 50 mm x 50 mm As required
38 Cable ties 4 ldquo As required
39 Flexible wires 075 mm As required
40 PVC Connectors 5 A amp 20 A 240 V As required
41 Terminal block 20A 240Vac As required
Procedures
5 Identify each component according to specification and quantity required from the schematic
diagram attached
6 Test the functionality of each component by using multi-meter or power supply whichever
applicable
7 Wire component according to circuit diagram
8 Three motors operated in sequence by DOL starter operated by manual push button or time
delay relay
a One loop per-cycle
b Continuous operation in a loop
c optional circuit design to represent the same task
d Only one out of three motors to be operated at a time (quiz)
9 Test the functionality of completed project
80 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
BASIC DESIGN INDUSTRIAL MOTOR CONTROL (SEQUENCE CONTROL)
THREE PHASE INDUCTION MOTOR OPERATED IN SEQUENCE BY DIRECT ON LINE
STARTER
LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
81 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
82 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Lcd lamp indicator 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
11 Overload Relay 415V 20A 3
12 Three phase induction motor 5 hp 3
13 Single phase step down transformer 2500VA 1
14 Single core PVC insulated Cable 1mm 2 As required
15 Single core PVC insulated Cable 25mm 2 As required
16 DIN rail 35 mm As required
17 PVC type Cable tray 50 mm x 50 mm As required
18 Cable ties 4 ldquo As required
19 Flexible wires 1 mm Oslash As required
20 PVC Terminal block 10A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the schematic
diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a optional exercise
i Forward Reverse dahlander motor
4 Test the functionality of completed project
83 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
THREE PHASE DAHLANDER TYPE INDUCTION MOTOR OPERATED FORWARD AND
REVERSE OPERATION BY DIRECT ON LINE STARTER
84 ndash 99EASYTECH ENTERPRISE
LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
Introduction
If a motors windings are connected in the star configuration any two phases will be in series across
the supply and hence the line current will be smaller(by 577) than if the windings were connected in
the delta arrangement
Hence larger-type motors with heavy starting currents are first connected in star and then when the
starting currents fall in delta This of course means that all six of the ends of the windings must be
brought to terminations outside the casing (Fig 833)
EZTECH
EZTECH ELECTRICAL INSTALLATION GUIDE
The automatic version of this starter incorporates a timing relay which automatically changes the
connections from star to delta Figs 834 and 835 show the wiring and schematic diagrams for a star
delta starter
Objectives
1 Identify component and the specification
2 Design forward reverse star delta starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
2 ndash 99EASYTECH ENTERPRISE
REV -C
LEGENDMCCB Moulded Case Circuit BreakerTOR Thermal Over Load RelayFOW-C Mains Forward ContactorREV-C Mains Reverse ContactorDC Delta ContactorSC Star ContactorS-SW Mains Selector Switch
SC
V2
W2
U2
DC
V1
W1
U1
TOR
TOR
FOW-C
30A MCCB
TOR
MAIN CIRCUIT FORWARD REVERSE STAR DELTA
RYBN S
-SW
3 PHASEINDUCTION MOTOR
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Relay 10 A 240V 3
5 Triple pole Contactor
6 cw NO NC auxiliary contact
240Vac 20 A 4
7 Overload Relay 415 V 1
8 LED indicator 240vac 5 A 4
9 Start stop button 240Vac 5A 2
10 DIN rail 35 mm As required
11 Flexible wires 1 mm As required
12 Single core PVC insulated
wire
25 mm As required
13 Terminal block 20 A As required
14 Squirrel cage motor 5kW 1
15 5 pin plug and socket 415V 20A 1
16 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
3 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
a Manual star delta
b Manual Forward reverse star delta starter
c Automatic star delta starter
d Automatic Forward reverse star delta starter
4 Test the functionality of completed project
4 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
Objectives
1 Identify component and the specification
2 Design auto transformer starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
5 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Autotransformer starter is used to start a 3 phase induction motor that has a rating between 10 to 15 hp
6 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Autotransformer set 10Kw 415 V 50 Hz 1
5 Triple pole Contactor 240Vac 4
6 Batten type Lamp holder 240 Vac 105 A 4
7 Start stop button 240Vac 10A 4
8 Filament lamp (Bulb ) 240Vac 40W 4
9 DIN rail 35 mm As required
10 Flexible wires 1 mm As required
7 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
11 Single core PVC insulated
wire
25 mm As required
12 Terminal block 20 A As required
13 Squirrel cage motor 10kW 1
14 5 pin plug and socket 415V 20A 1
15 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a open transient autotransformer starter
b close transient autotransformer starter
c Forward reverse autotransformer starter
4 Test the functionality of completed project
8 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
Objectives
1 Identify component and the specification
2 Design rotor resistance starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
9 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Rotor Resistor set 10kW 1
5 Triple pole Contactor 240Vac 20A 4
6 Indicating light 240vac 5 A 4
7 Start stop push button 240Vac 5A 4
8 DIN rail 35 mm As required
9 Flexible wires 1 mm 2 As required
10 Single core PVC insulated wire 25 mm 2 As required
11 Terminal block 20 A As required
12 Slip Ring motor 10kW 1
13 5 pin round 3 phase socket 415V 20A 1
14 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
10 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
4 Test the functionality of completed project
a Dead circuit test b Life circuit test
5 Measure starting and running Amps
LESSON 16
TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
An installation in general will suffer damage
Damage usually occurs on the electric motor control as follows
1 Damage to the main circuit
2 Damage to the control circuit
The cause of the damage
i Overcurrent overload short circuit
ii Leakage current to ground
iii Equipment malfunction
iv The main control circuit
a Trip of main circuit protection devices fire
b Defect of motor terminal such as short circuit fire loose
v The control circuit is not functioning -
a contactor relay relay time overload relay does not work damaged burned
b Loose cable connection disconnected
Detecting and Repairing Damage
Examples of damage are as follows
i Motor does not work
ii Motor function and overload relay trips
iii Motor function but only partially functional control circuit
Methods of detecting damage
Among the known methods necessary to detect damage are as follows
1 Turn off the electricity at the main switch (main switch) in order to avoid any danger during the
work carried out to detect damage
2 Check all the protective gear that controls the motor control main circuit
11 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
3 Make sure the damage function control circuit
4 Check the control circuit according to the schematic circuit diagram of the motor control
5 Check the operation of the control circuit
Note
Use wiring that has been installed on the SYSTEM OF MOTOR CONTROL BOARD by Forward
Reverse control circuit for Star Delta to test and look for damage
SELF-ASSESSMENT QUESTIONS
1 (a) Explain what is meant by the term lsquoback emfrsquo in a motor
(b) Outline the basic differences between series shunt and compound wound dc motors
2 (a) With the aid of diagrams explain how the speed of series shunt and compound-wound motors
may be controlled
(b) A 440V dc shunt-wound motor has a field resistance of 200R and an armature resistance of 06 R
When its speed is 20 rev d second the current drawn from the supply is 122A Calculate its back
emf at this speed If the speed were decreased to 19 revssecond the field flux remaining unchanged
calculate the new back emf and the new armature current
3 A load of 64 kW at 240 V is supplied from the terminals of a shunt-wound dc generator The field
resistance is 180 A Calculate the armature current
4 (a) Explain with the aid of a diagram how a rotating magnetic field may be
(b) What is meant by lsquosynchronous speedrsquo
Calculate the synchronous obtained speed of a 12 pole motor if the supply frequency is 50Hz
5 (a) Explain the action of a synchronous motor
(b) What methods are available to start a synchronous motor Explain with diagrams
6 (a) Explain the action of a cage induction motor
(b) What is meant by the term lsquosliprsquo
Calculate the percentage slip of a six pole induction motor running at 162 revssecond from a 50 Hz
supply
7 Describe with sketches three different ways of starting a single-phase induction motor
12 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
8 Explain with the aid of a sketch the action of a three-phase DOL starter
What are dashpots used for How are remote start and stop buttons connected
9 A I0 kW 240V 50Hz single-phase cage rotor induction motor is 85efficient and has a PF of 068
lagging Calculate the motor current and the value of capacitor required to raise the PF to 093
lagging
10 Calculate the torque developed by an 18 kW four-pole induction motor run at 35 slip from a
50Hz supply
APPENDIX 1
13 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 11
14 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 111
Attachment Reference
httpswwwtlc-directcoukBook621htm
httpwwwstgovmyindexphpms
15 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Residual Current Device Testi Ensure that the residual current device (RCD) trips within the set time on the occurrence of current
leakage to earth
ii Test Equipment ndash RCD Tester RCCB Tester
iii Test Method 1
1 1048766 Use the Trip Test Button
2 1048766 Press the trip button found on the RCD to determine if it trips or otherwise This test would
not be able to determine the sensitivity of the RCD nor the time taken for it to trip
iv Test Method 2
i 1048766 Use a RCD Tester
ii This equipment is equipped with a 13A plug which can be connected to a 13A socket outlet
Select the RCD sensitivity to be the same as the sensitivity of the RCD to be tested to
determine if the RCD can trip The time to trip shall not exceed 40 mS
iii 1048766 Test method ndash
a) Position the selection switch in accordance with the sensitivity of the RCD used
Example 100 mA 01 A
b) Position the operations switch to lsquoNo Triprsquo (frac12 Rated mA = 50) connect the 3 pin plug to
the 13A socket outlet
67 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
c) Switch on the 13A socket outlet ndash ensure that the P-N and P-E lights light up
This shows that the polarity is correct (Note if both the lights as above do not light up the test cannot
be continued)
d) Press the test button ndash the reading shows less than 200 mS and simultaneously the lsquotestrsquo light lights
up and the P-N and P-E lights do not light up At that instant the RCD will not trip
e) Move the selection switch to 180o (+ve wave) ndash repeat steps (d) and (e) Move the operations
switch to lsquoTriprsquo (Rated mA = 100)
g) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200mS
h) Move the selection switch to 0o (-ve wave)
i) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
j) The above test is repeated until a near correct reading is obtained
k) Record the test results
l) Change the operations switch to lsquoFast Triprsquo and press the test button ndash RCD will trip within a
time not exceeding 40 millisecond
m) Repeat a number of times at 0o or 180o
On completion of a wiring installation a number of tests on the installation have to be conducted to
ascertain that the wiring circuits and connected appliances are safe for use Prior to carrying out the
tests an inspection has to be done the following tests shall be conducted
i Continuity Test
ii Insulation Resistance Test
iii Polarity Test
iv Earth Electrode Resistance test and
v Residual Current Device Test
821 Continuity Test
There are 3 main types of continuity tests for the final circuits-
i Protection Conductor Continuity Test
ii Final Ring Circuit Conductor Continuity Test
68 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
iii Live and Neutral Conductor Continuity Test
a) Protection Conductor Continuity Test
bull To ascertain that all protection conductors are connected in the correct and effective manner
bull Test equipment ndash Multimeter (Ohm range) or Ohm meter
bull Test Method
1 1048766 Ensure that the main switch RCD and MCB are open circuited (switched off) and all loads are
disconnected
2 1048766 Connected the test leads as in the Figure 81
3 1048766 The meter reading shall be less than 1 Ω
Final Ring Circuit Conductor Continuity Test
bull To ensure that all conductors around the ring circuit have continuity
bull Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
bull Test Method
1 1048766 Disconnect both the supply source live conductors from the MCB the neutral conductor
from the neutral terminals and the earth conductor from the earth terminal in the distribution
fuse box
2 1048766 Connect the test leads as in the Figure 82 (EE)
3 1048766 Repeat the procedure for (L-L) and (N-N)
4 1048766 The meter reading value shall be less than 1 ohm Figure 82 - Final Ring Circuit Conductor
Continuity Test Ohm Meter
Disconnect both the supply source cables from mcbfuse
Take readings at earth conductors of both sources and note resistance readings
Live and Neutral Conductor Continuity Test
1 To ensure that each conductor in the circuit has continuity
2 Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
3 Test Method
1 1048766 Switch off the Main switch RCD and MCB
2 1048766 Disconnect all loads
3 1048766 Switch on all switches in the circuit
4 1048766 Disconnect the fusesfinal circuit breakers and close the circuit
5 1048766 Carry out the test as shown in Figure 83
6 1048766 The meter reading value shall be less than 1 ohm Figure 83 - Live and Neutral
Conductor Continuity Test Ohm Meter
Insulation Resistance Test
69 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
i Ensure that there is no leakage current between phase conductors phase and neutral conductors and
phase conductor and earth
ii Test the strength of the cable insulation
iii Test Equipment ndash Insulation Resistance Tester Operating voltage is 250VDC or 500VDC
iv Test Method
1 1048766 Switch off main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in the Table below
5 1048766 Meter reading value shall be less than 1 Megaohm
Polarity Test
i Ensure that each fuse or single pole control and protection device is connected only in the phase
conductor
ii Intermediate contact of Edison screw lamp holder is connected to the phase conductor
iii Ensure that phase neutral and earth conductors at socket outlets are connected at the correct
terminals
iv Test Equipment ndash Multimeter (Ohm range) or Ohm meter
v Test Method
1 1048766 Switch off Main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in Figure 85
5 1048766 Test switches and single phase control devices at the phase conductors
6 1048766 Test socket outlet connection sources
7 1048766 Test Edison screw lamp holder connections
8 1048766 Meter reading value shall be less than 1 Ω
Earth Electrode Resistance Test
i To test the earth electrode resistance
70 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
ii To ascertain the suitability of the location of the electrode
iii To ensure that the electrode is not buried within the resistance area of another electrode
iv Test equipment ndash Earth Resistance Tester
v Test method -
1 1048766 Terminal rsquoErsquo is connected to the electrode to be tested (green conductor)
2 1048766 Terminal lsquoPrsquo is connected to the potential spike (yellow conductor) at a distance of 10
meters from the earth electrode
3 1048766 Terminal lsquoCrsquo is connected to the current spike (red conductor) at a distance of 20 meters
from the earth electrode E P C Electrode 10 meter 10 meter
Figure 86 ndash Earth Electrode Resistance Measurement Test Equipment
Earth Electrode Resistance Measurement Method (Figure 86)
This test must be repeated at least three times to ensure that the reading is not affected by interacting
earthing regions
i Record the first reading (Z1) Example Z1 = 10 Ω
ii Move the voltage spike to a distance of 6 meters from the original position Record the second
reading (Z2) Example Z2 = 10 Ω
iii Move the voltage spike to a distance of 6 meters from the original position Record the third
reading (Z3)
Example Z3 = 10 Ω
Residual Current Device Test
71 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
i Ensure that the residual current device (RCD) trips within the set time on the occurrence of current
leakage to earth
ii Test Equipment ndash RCD Tester RCCB Tester
iii Test Method 1
1 1048766 Use the Trip Test Button
2 1048766 Press the trip button found on the RCD to determine if it trips or otherwise This test would
not be able to determine the sensitivity of the RCD nor the time taken for it to trip
iv Test Method 2
1048766 Use a RCD Tester
This equipment is equipped with a 13A plug which can be connected to a 13A socket outlet Select the
RCD sensitivity to be the same as the sensitivity of the RCD to be tested to determine if the RCD can
trip The time to trip shall not exceed 40 mS
1048766 Test method ndash
a) Position the selection switch in accordance with the sensitivity of the RCD used
Example 100 mA 01 A
b) Position the operations switch to lsquoNo Triprsquo (frac12 Rated mA = 50) connect the 3 pin plug to
the 13A socket outlet
c) Switch on the 13A socket outlet ndash ensure that the P-N and P-E lights light up This shows that
the polarity is correct (Note if both the lights as above do not light up the test cannot be
continued)
d) Press the test button ndash the reading shows less than 200 millisecond and simultaneously the
lsquotestrsquo light lights up and the P-N and P-E lights do not light up At that instant the RCD will
not trip
e) Move the selection switch to 180o (+ve wave) ndash repeat steps (d) and (e) = 100)
f) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
g) Move the selection switch to 0o (-ve wave)
h) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
i) The above test is repeated until a near correct reading is obtained
j) Record the test results
k) Change the operations switch to lsquoFast Triprsquo and press the test button ndash RCD will trip within a
time not exceeding 40 mS
l) Repeat a number of times at 0o or 180o
72 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 9 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (DC)
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
73 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Start stop button 240Vac 5A 2
9 Filament lamp (Bulb ) 240Vac 40W 3
10 Overload Relay 415V 20A 3
11 Three phase induction motor 5 hp 3
12 Single phase step down transformer 2500VA 1
13 Single core PVC insulated Cable 1mm 2 As required
14 Single core PVC insulated Cable 25mm 2 As required
15 DIN rail 35 mm As required
16 PVC type Cable tray 50 mm x 50 mm As required
17 Cable ties 4 ldquo As required
18 Flexible wires 05 mm As required
19 PVC Connectors 5 A amp 20 A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the schematic
diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a optional exercise
i Simple DOL starter
ii Forward reverse DOL starter
iii Forward Reverse Dahlander motor
iv Three motors operated in sequence by DOL starter operated by manual push
button or time delay relay
74 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
a One loop per-cycle
b Continuous operation in a loop
c optional circuit design to represent the same task
v Only one out of three motors to be operated at a time (quiz)
4 Test the functionality of completed project
LESSON 10 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (AC)
75 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 1
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Lamp point 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
76 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
11 Overload Relay 415V 20A 3
12 Three phase induction
motor
5 hp 3
13 Single core PVC insulated
Cable
1mm 2 As required
14 Single core PVC insulated
Cable
25mm 2 As required
15 DIN rail 35 mm As required
16 PVC type Cable tray 50 mm x 50 mm As required
17 Cable ties 4 ldquo As required
18 Flexible wires 05 mm As required
19 PVC Connectors 5 A amp 20 A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the
schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram optional exercise
4 Simple DOL starter
5 Forward reverse DOL starter
6 Test the functionality of completed project
77 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 1
78 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
cm
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Indicating light 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
11 Overload Relay 415V 20A 3
12 Three phase induction motor 5 hp 3
13 Single phase step down
transformer
2500VA 1
14 Single core PVC insulated
Cable
1mm 2 As required
15 Single core PVC insulated
Cable
25mm 2 As required
16 DIN rail 35 mm As required
17 PVC type Cable tray 50 mm x 50 mm As required
18 Cable ties 4 ldquo As required
19 Flexible wires 05 mm As required
20 PVC Connectors 5 A amp 20 A 240 V As required
21 Single pole MCB 6A 240 V 1
22 Single pole MCB 2A 240 V 1
23 Triple pole MCB 20A 415 V 1
24 Mounting board 30 cm x 40 cm x 3
cm
1
25 Relay cw 11 pin socket 10 A 240 Vac 2
26 Time delay relay 10 A 240 Vac 3
27 Triple pole Contactor 20A 240Vac 3
28 Batten type Lamp holder 240Vac 10 A 3
29 Start stop button 240Vac 10A 2
30 Indicating light (Bulb ) 240Vac 25W 3
31 Overload Relay 415V 20A 1
32 Three phase dahlander type
induction motor
5 hp 1
33 Single phase step down
transformer
24024Vac
2500VA
1
79 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
34 Single core PVC insulated
Cable
1mm 2 As required
35 Single core PVC insulated
Cable
25mm 2 As required
36 DIN rail 35 mm As required
37 PVC type Cable tray 50 mm x 50 mm As required
38 Cable ties 4 ldquo As required
39 Flexible wires 075 mm As required
40 PVC Connectors 5 A amp 20 A 240 V As required
41 Terminal block 20A 240Vac As required
Procedures
5 Identify each component according to specification and quantity required from the schematic
diagram attached
6 Test the functionality of each component by using multi-meter or power supply whichever
applicable
7 Wire component according to circuit diagram
8 Three motors operated in sequence by DOL starter operated by manual push button or time
delay relay
a One loop per-cycle
b Continuous operation in a loop
c optional circuit design to represent the same task
d Only one out of three motors to be operated at a time (quiz)
9 Test the functionality of completed project
80 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
BASIC DESIGN INDUSTRIAL MOTOR CONTROL (SEQUENCE CONTROL)
THREE PHASE INDUCTION MOTOR OPERATED IN SEQUENCE BY DIRECT ON LINE
STARTER
LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
81 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
82 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Lcd lamp indicator 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
11 Overload Relay 415V 20A 3
12 Three phase induction motor 5 hp 3
13 Single phase step down transformer 2500VA 1
14 Single core PVC insulated Cable 1mm 2 As required
15 Single core PVC insulated Cable 25mm 2 As required
16 DIN rail 35 mm As required
17 PVC type Cable tray 50 mm x 50 mm As required
18 Cable ties 4 ldquo As required
19 Flexible wires 1 mm Oslash As required
20 PVC Terminal block 10A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the schematic
diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a optional exercise
i Forward Reverse dahlander motor
4 Test the functionality of completed project
83 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
THREE PHASE DAHLANDER TYPE INDUCTION MOTOR OPERATED FORWARD AND
REVERSE OPERATION BY DIRECT ON LINE STARTER
84 ndash 99EASYTECH ENTERPRISE
LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
Introduction
If a motors windings are connected in the star configuration any two phases will be in series across
the supply and hence the line current will be smaller(by 577) than if the windings were connected in
the delta arrangement
Hence larger-type motors with heavy starting currents are first connected in star and then when the
starting currents fall in delta This of course means that all six of the ends of the windings must be
brought to terminations outside the casing (Fig 833)
EZTECH
EZTECH ELECTRICAL INSTALLATION GUIDE
The automatic version of this starter incorporates a timing relay which automatically changes the
connections from star to delta Figs 834 and 835 show the wiring and schematic diagrams for a star
delta starter
Objectives
1 Identify component and the specification
2 Design forward reverse star delta starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
2 ndash 99EASYTECH ENTERPRISE
REV -C
LEGENDMCCB Moulded Case Circuit BreakerTOR Thermal Over Load RelayFOW-C Mains Forward ContactorREV-C Mains Reverse ContactorDC Delta ContactorSC Star ContactorS-SW Mains Selector Switch
SC
V2
W2
U2
DC
V1
W1
U1
TOR
TOR
FOW-C
30A MCCB
TOR
MAIN CIRCUIT FORWARD REVERSE STAR DELTA
RYBN S
-SW
3 PHASEINDUCTION MOTOR
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Relay 10 A 240V 3
5 Triple pole Contactor
6 cw NO NC auxiliary contact
240Vac 20 A 4
7 Overload Relay 415 V 1
8 LED indicator 240vac 5 A 4
9 Start stop button 240Vac 5A 2
10 DIN rail 35 mm As required
11 Flexible wires 1 mm As required
12 Single core PVC insulated
wire
25 mm As required
13 Terminal block 20 A As required
14 Squirrel cage motor 5kW 1
15 5 pin plug and socket 415V 20A 1
16 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
3 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
a Manual star delta
b Manual Forward reverse star delta starter
c Automatic star delta starter
d Automatic Forward reverse star delta starter
4 Test the functionality of completed project
4 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
Objectives
1 Identify component and the specification
2 Design auto transformer starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
5 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Autotransformer starter is used to start a 3 phase induction motor that has a rating between 10 to 15 hp
6 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Autotransformer set 10Kw 415 V 50 Hz 1
5 Triple pole Contactor 240Vac 4
6 Batten type Lamp holder 240 Vac 105 A 4
7 Start stop button 240Vac 10A 4
8 Filament lamp (Bulb ) 240Vac 40W 4
9 DIN rail 35 mm As required
10 Flexible wires 1 mm As required
7 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
11 Single core PVC insulated
wire
25 mm As required
12 Terminal block 20 A As required
13 Squirrel cage motor 10kW 1
14 5 pin plug and socket 415V 20A 1
15 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a open transient autotransformer starter
b close transient autotransformer starter
c Forward reverse autotransformer starter
4 Test the functionality of completed project
8 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
Objectives
1 Identify component and the specification
2 Design rotor resistance starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
9 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Rotor Resistor set 10kW 1
5 Triple pole Contactor 240Vac 20A 4
6 Indicating light 240vac 5 A 4
7 Start stop push button 240Vac 5A 4
8 DIN rail 35 mm As required
9 Flexible wires 1 mm 2 As required
10 Single core PVC insulated wire 25 mm 2 As required
11 Terminal block 20 A As required
12 Slip Ring motor 10kW 1
13 5 pin round 3 phase socket 415V 20A 1
14 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
10 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
4 Test the functionality of completed project
a Dead circuit test b Life circuit test
5 Measure starting and running Amps
LESSON 16
TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
An installation in general will suffer damage
Damage usually occurs on the electric motor control as follows
1 Damage to the main circuit
2 Damage to the control circuit
The cause of the damage
i Overcurrent overload short circuit
ii Leakage current to ground
iii Equipment malfunction
iv The main control circuit
a Trip of main circuit protection devices fire
b Defect of motor terminal such as short circuit fire loose
v The control circuit is not functioning -
a contactor relay relay time overload relay does not work damaged burned
b Loose cable connection disconnected
Detecting and Repairing Damage
Examples of damage are as follows
i Motor does not work
ii Motor function and overload relay trips
iii Motor function but only partially functional control circuit
Methods of detecting damage
Among the known methods necessary to detect damage are as follows
1 Turn off the electricity at the main switch (main switch) in order to avoid any danger during the
work carried out to detect damage
2 Check all the protective gear that controls the motor control main circuit
11 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
3 Make sure the damage function control circuit
4 Check the control circuit according to the schematic circuit diagram of the motor control
5 Check the operation of the control circuit
Note
Use wiring that has been installed on the SYSTEM OF MOTOR CONTROL BOARD by Forward
Reverse control circuit for Star Delta to test and look for damage
SELF-ASSESSMENT QUESTIONS
1 (a) Explain what is meant by the term lsquoback emfrsquo in a motor
(b) Outline the basic differences between series shunt and compound wound dc motors
2 (a) With the aid of diagrams explain how the speed of series shunt and compound-wound motors
may be controlled
(b) A 440V dc shunt-wound motor has a field resistance of 200R and an armature resistance of 06 R
When its speed is 20 rev d second the current drawn from the supply is 122A Calculate its back
emf at this speed If the speed were decreased to 19 revssecond the field flux remaining unchanged
calculate the new back emf and the new armature current
3 A load of 64 kW at 240 V is supplied from the terminals of a shunt-wound dc generator The field
resistance is 180 A Calculate the armature current
4 (a) Explain with the aid of a diagram how a rotating magnetic field may be
(b) What is meant by lsquosynchronous speedrsquo
Calculate the synchronous obtained speed of a 12 pole motor if the supply frequency is 50Hz
5 (a) Explain the action of a synchronous motor
(b) What methods are available to start a synchronous motor Explain with diagrams
6 (a) Explain the action of a cage induction motor
(b) What is meant by the term lsquosliprsquo
Calculate the percentage slip of a six pole induction motor running at 162 revssecond from a 50 Hz
supply
7 Describe with sketches three different ways of starting a single-phase induction motor
12 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
8 Explain with the aid of a sketch the action of a three-phase DOL starter
What are dashpots used for How are remote start and stop buttons connected
9 A I0 kW 240V 50Hz single-phase cage rotor induction motor is 85efficient and has a PF of 068
lagging Calculate the motor current and the value of capacitor required to raise the PF to 093
lagging
10 Calculate the torque developed by an 18 kW four-pole induction motor run at 35 slip from a
50Hz supply
APPENDIX 1
13 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 11
14 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 111
Attachment Reference
httpswwwtlc-directcoukBook621htm
httpwwwstgovmyindexphpms
15 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
c) Switch on the 13A socket outlet ndash ensure that the P-N and P-E lights light up
This shows that the polarity is correct (Note if both the lights as above do not light up the test cannot
be continued)
d) Press the test button ndash the reading shows less than 200 mS and simultaneously the lsquotestrsquo light lights
up and the P-N and P-E lights do not light up At that instant the RCD will not trip
e) Move the selection switch to 180o (+ve wave) ndash repeat steps (d) and (e) Move the operations
switch to lsquoTriprsquo (Rated mA = 100)
g) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200mS
h) Move the selection switch to 0o (-ve wave)
i) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
j) The above test is repeated until a near correct reading is obtained
k) Record the test results
l) Change the operations switch to lsquoFast Triprsquo and press the test button ndash RCD will trip within a
time not exceeding 40 millisecond
m) Repeat a number of times at 0o or 180o
On completion of a wiring installation a number of tests on the installation have to be conducted to
ascertain that the wiring circuits and connected appliances are safe for use Prior to carrying out the
tests an inspection has to be done the following tests shall be conducted
i Continuity Test
ii Insulation Resistance Test
iii Polarity Test
iv Earth Electrode Resistance test and
v Residual Current Device Test
821 Continuity Test
There are 3 main types of continuity tests for the final circuits-
i Protection Conductor Continuity Test
ii Final Ring Circuit Conductor Continuity Test
68 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
iii Live and Neutral Conductor Continuity Test
a) Protection Conductor Continuity Test
bull To ascertain that all protection conductors are connected in the correct and effective manner
bull Test equipment ndash Multimeter (Ohm range) or Ohm meter
bull Test Method
1 1048766 Ensure that the main switch RCD and MCB are open circuited (switched off) and all loads are
disconnected
2 1048766 Connected the test leads as in the Figure 81
3 1048766 The meter reading shall be less than 1 Ω
Final Ring Circuit Conductor Continuity Test
bull To ensure that all conductors around the ring circuit have continuity
bull Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
bull Test Method
1 1048766 Disconnect both the supply source live conductors from the MCB the neutral conductor
from the neutral terminals and the earth conductor from the earth terminal in the distribution
fuse box
2 1048766 Connect the test leads as in the Figure 82 (EE)
3 1048766 Repeat the procedure for (L-L) and (N-N)
4 1048766 The meter reading value shall be less than 1 ohm Figure 82 - Final Ring Circuit Conductor
Continuity Test Ohm Meter
Disconnect both the supply source cables from mcbfuse
Take readings at earth conductors of both sources and note resistance readings
Live and Neutral Conductor Continuity Test
1 To ensure that each conductor in the circuit has continuity
2 Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
3 Test Method
1 1048766 Switch off the Main switch RCD and MCB
2 1048766 Disconnect all loads
3 1048766 Switch on all switches in the circuit
4 1048766 Disconnect the fusesfinal circuit breakers and close the circuit
5 1048766 Carry out the test as shown in Figure 83
6 1048766 The meter reading value shall be less than 1 ohm Figure 83 - Live and Neutral
Conductor Continuity Test Ohm Meter
Insulation Resistance Test
69 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
i Ensure that there is no leakage current between phase conductors phase and neutral conductors and
phase conductor and earth
ii Test the strength of the cable insulation
iii Test Equipment ndash Insulation Resistance Tester Operating voltage is 250VDC or 500VDC
iv Test Method
1 1048766 Switch off main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in the Table below
5 1048766 Meter reading value shall be less than 1 Megaohm
Polarity Test
i Ensure that each fuse or single pole control and protection device is connected only in the phase
conductor
ii Intermediate contact of Edison screw lamp holder is connected to the phase conductor
iii Ensure that phase neutral and earth conductors at socket outlets are connected at the correct
terminals
iv Test Equipment ndash Multimeter (Ohm range) or Ohm meter
v Test Method
1 1048766 Switch off Main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in Figure 85
5 1048766 Test switches and single phase control devices at the phase conductors
6 1048766 Test socket outlet connection sources
7 1048766 Test Edison screw lamp holder connections
8 1048766 Meter reading value shall be less than 1 Ω
Earth Electrode Resistance Test
i To test the earth electrode resistance
70 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
ii To ascertain the suitability of the location of the electrode
iii To ensure that the electrode is not buried within the resistance area of another electrode
iv Test equipment ndash Earth Resistance Tester
v Test method -
1 1048766 Terminal rsquoErsquo is connected to the electrode to be tested (green conductor)
2 1048766 Terminal lsquoPrsquo is connected to the potential spike (yellow conductor) at a distance of 10
meters from the earth electrode
3 1048766 Terminal lsquoCrsquo is connected to the current spike (red conductor) at a distance of 20 meters
from the earth electrode E P C Electrode 10 meter 10 meter
Figure 86 ndash Earth Electrode Resistance Measurement Test Equipment
Earth Electrode Resistance Measurement Method (Figure 86)
This test must be repeated at least three times to ensure that the reading is not affected by interacting
earthing regions
i Record the first reading (Z1) Example Z1 = 10 Ω
ii Move the voltage spike to a distance of 6 meters from the original position Record the second
reading (Z2) Example Z2 = 10 Ω
iii Move the voltage spike to a distance of 6 meters from the original position Record the third
reading (Z3)
Example Z3 = 10 Ω
Residual Current Device Test
71 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
i Ensure that the residual current device (RCD) trips within the set time on the occurrence of current
leakage to earth
ii Test Equipment ndash RCD Tester RCCB Tester
iii Test Method 1
1 1048766 Use the Trip Test Button
2 1048766 Press the trip button found on the RCD to determine if it trips or otherwise This test would
not be able to determine the sensitivity of the RCD nor the time taken for it to trip
iv Test Method 2
1048766 Use a RCD Tester
This equipment is equipped with a 13A plug which can be connected to a 13A socket outlet Select the
RCD sensitivity to be the same as the sensitivity of the RCD to be tested to determine if the RCD can
trip The time to trip shall not exceed 40 mS
1048766 Test method ndash
a) Position the selection switch in accordance with the sensitivity of the RCD used
Example 100 mA 01 A
b) Position the operations switch to lsquoNo Triprsquo (frac12 Rated mA = 50) connect the 3 pin plug to
the 13A socket outlet
c) Switch on the 13A socket outlet ndash ensure that the P-N and P-E lights light up This shows that
the polarity is correct (Note if both the lights as above do not light up the test cannot be
continued)
d) Press the test button ndash the reading shows less than 200 millisecond and simultaneously the
lsquotestrsquo light lights up and the P-N and P-E lights do not light up At that instant the RCD will
not trip
e) Move the selection switch to 180o (+ve wave) ndash repeat steps (d) and (e) = 100)
f) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
g) Move the selection switch to 0o (-ve wave)
h) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
i) The above test is repeated until a near correct reading is obtained
j) Record the test results
k) Change the operations switch to lsquoFast Triprsquo and press the test button ndash RCD will trip within a
time not exceeding 40 mS
l) Repeat a number of times at 0o or 180o
72 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 9 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (DC)
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
73 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Start stop button 240Vac 5A 2
9 Filament lamp (Bulb ) 240Vac 40W 3
10 Overload Relay 415V 20A 3
11 Three phase induction motor 5 hp 3
12 Single phase step down transformer 2500VA 1
13 Single core PVC insulated Cable 1mm 2 As required
14 Single core PVC insulated Cable 25mm 2 As required
15 DIN rail 35 mm As required
16 PVC type Cable tray 50 mm x 50 mm As required
17 Cable ties 4 ldquo As required
18 Flexible wires 05 mm As required
19 PVC Connectors 5 A amp 20 A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the schematic
diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a optional exercise
i Simple DOL starter
ii Forward reverse DOL starter
iii Forward Reverse Dahlander motor
iv Three motors operated in sequence by DOL starter operated by manual push
button or time delay relay
74 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
a One loop per-cycle
b Continuous operation in a loop
c optional circuit design to represent the same task
v Only one out of three motors to be operated at a time (quiz)
4 Test the functionality of completed project
LESSON 10 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (AC)
75 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 1
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Lamp point 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
76 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
11 Overload Relay 415V 20A 3
12 Three phase induction
motor
5 hp 3
13 Single core PVC insulated
Cable
1mm 2 As required
14 Single core PVC insulated
Cable
25mm 2 As required
15 DIN rail 35 mm As required
16 PVC type Cable tray 50 mm x 50 mm As required
17 Cable ties 4 ldquo As required
18 Flexible wires 05 mm As required
19 PVC Connectors 5 A amp 20 A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the
schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram optional exercise
4 Simple DOL starter
5 Forward reverse DOL starter
6 Test the functionality of completed project
77 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 1
78 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
cm
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Indicating light 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
11 Overload Relay 415V 20A 3
12 Three phase induction motor 5 hp 3
13 Single phase step down
transformer
2500VA 1
14 Single core PVC insulated
Cable
1mm 2 As required
15 Single core PVC insulated
Cable
25mm 2 As required
16 DIN rail 35 mm As required
17 PVC type Cable tray 50 mm x 50 mm As required
18 Cable ties 4 ldquo As required
19 Flexible wires 05 mm As required
20 PVC Connectors 5 A amp 20 A 240 V As required
21 Single pole MCB 6A 240 V 1
22 Single pole MCB 2A 240 V 1
23 Triple pole MCB 20A 415 V 1
24 Mounting board 30 cm x 40 cm x 3
cm
1
25 Relay cw 11 pin socket 10 A 240 Vac 2
26 Time delay relay 10 A 240 Vac 3
27 Triple pole Contactor 20A 240Vac 3
28 Batten type Lamp holder 240Vac 10 A 3
29 Start stop button 240Vac 10A 2
30 Indicating light (Bulb ) 240Vac 25W 3
31 Overload Relay 415V 20A 1
32 Three phase dahlander type
induction motor
5 hp 1
33 Single phase step down
transformer
24024Vac
2500VA
1
79 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
34 Single core PVC insulated
Cable
1mm 2 As required
35 Single core PVC insulated
Cable
25mm 2 As required
36 DIN rail 35 mm As required
37 PVC type Cable tray 50 mm x 50 mm As required
38 Cable ties 4 ldquo As required
39 Flexible wires 075 mm As required
40 PVC Connectors 5 A amp 20 A 240 V As required
41 Terminal block 20A 240Vac As required
Procedures
5 Identify each component according to specification and quantity required from the schematic
diagram attached
6 Test the functionality of each component by using multi-meter or power supply whichever
applicable
7 Wire component according to circuit diagram
8 Three motors operated in sequence by DOL starter operated by manual push button or time
delay relay
a One loop per-cycle
b Continuous operation in a loop
c optional circuit design to represent the same task
d Only one out of three motors to be operated at a time (quiz)
9 Test the functionality of completed project
80 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
BASIC DESIGN INDUSTRIAL MOTOR CONTROL (SEQUENCE CONTROL)
THREE PHASE INDUCTION MOTOR OPERATED IN SEQUENCE BY DIRECT ON LINE
STARTER
LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
81 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
82 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Lcd lamp indicator 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
11 Overload Relay 415V 20A 3
12 Three phase induction motor 5 hp 3
13 Single phase step down transformer 2500VA 1
14 Single core PVC insulated Cable 1mm 2 As required
15 Single core PVC insulated Cable 25mm 2 As required
16 DIN rail 35 mm As required
17 PVC type Cable tray 50 mm x 50 mm As required
18 Cable ties 4 ldquo As required
19 Flexible wires 1 mm Oslash As required
20 PVC Terminal block 10A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the schematic
diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a optional exercise
i Forward Reverse dahlander motor
4 Test the functionality of completed project
83 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
THREE PHASE DAHLANDER TYPE INDUCTION MOTOR OPERATED FORWARD AND
REVERSE OPERATION BY DIRECT ON LINE STARTER
84 ndash 99EASYTECH ENTERPRISE
LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
Introduction
If a motors windings are connected in the star configuration any two phases will be in series across
the supply and hence the line current will be smaller(by 577) than if the windings were connected in
the delta arrangement
Hence larger-type motors with heavy starting currents are first connected in star and then when the
starting currents fall in delta This of course means that all six of the ends of the windings must be
brought to terminations outside the casing (Fig 833)
EZTECH
EZTECH ELECTRICAL INSTALLATION GUIDE
The automatic version of this starter incorporates a timing relay which automatically changes the
connections from star to delta Figs 834 and 835 show the wiring and schematic diagrams for a star
delta starter
Objectives
1 Identify component and the specification
2 Design forward reverse star delta starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
2 ndash 99EASYTECH ENTERPRISE
REV -C
LEGENDMCCB Moulded Case Circuit BreakerTOR Thermal Over Load RelayFOW-C Mains Forward ContactorREV-C Mains Reverse ContactorDC Delta ContactorSC Star ContactorS-SW Mains Selector Switch
SC
V2
W2
U2
DC
V1
W1
U1
TOR
TOR
FOW-C
30A MCCB
TOR
MAIN CIRCUIT FORWARD REVERSE STAR DELTA
RYBN S
-SW
3 PHASEINDUCTION MOTOR
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Relay 10 A 240V 3
5 Triple pole Contactor
6 cw NO NC auxiliary contact
240Vac 20 A 4
7 Overload Relay 415 V 1
8 LED indicator 240vac 5 A 4
9 Start stop button 240Vac 5A 2
10 DIN rail 35 mm As required
11 Flexible wires 1 mm As required
12 Single core PVC insulated
wire
25 mm As required
13 Terminal block 20 A As required
14 Squirrel cage motor 5kW 1
15 5 pin plug and socket 415V 20A 1
16 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
3 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
a Manual star delta
b Manual Forward reverse star delta starter
c Automatic star delta starter
d Automatic Forward reverse star delta starter
4 Test the functionality of completed project
4 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
Objectives
1 Identify component and the specification
2 Design auto transformer starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
5 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Autotransformer starter is used to start a 3 phase induction motor that has a rating between 10 to 15 hp
6 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Autotransformer set 10Kw 415 V 50 Hz 1
5 Triple pole Contactor 240Vac 4
6 Batten type Lamp holder 240 Vac 105 A 4
7 Start stop button 240Vac 10A 4
8 Filament lamp (Bulb ) 240Vac 40W 4
9 DIN rail 35 mm As required
10 Flexible wires 1 mm As required
7 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
11 Single core PVC insulated
wire
25 mm As required
12 Terminal block 20 A As required
13 Squirrel cage motor 10kW 1
14 5 pin plug and socket 415V 20A 1
15 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a open transient autotransformer starter
b close transient autotransformer starter
c Forward reverse autotransformer starter
4 Test the functionality of completed project
8 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
Objectives
1 Identify component and the specification
2 Design rotor resistance starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
9 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Rotor Resistor set 10kW 1
5 Triple pole Contactor 240Vac 20A 4
6 Indicating light 240vac 5 A 4
7 Start stop push button 240Vac 5A 4
8 DIN rail 35 mm As required
9 Flexible wires 1 mm 2 As required
10 Single core PVC insulated wire 25 mm 2 As required
11 Terminal block 20 A As required
12 Slip Ring motor 10kW 1
13 5 pin round 3 phase socket 415V 20A 1
14 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
10 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
4 Test the functionality of completed project
a Dead circuit test b Life circuit test
5 Measure starting and running Amps
LESSON 16
TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
An installation in general will suffer damage
Damage usually occurs on the electric motor control as follows
1 Damage to the main circuit
2 Damage to the control circuit
The cause of the damage
i Overcurrent overload short circuit
ii Leakage current to ground
iii Equipment malfunction
iv The main control circuit
a Trip of main circuit protection devices fire
b Defect of motor terminal such as short circuit fire loose
v The control circuit is not functioning -
a contactor relay relay time overload relay does not work damaged burned
b Loose cable connection disconnected
Detecting and Repairing Damage
Examples of damage are as follows
i Motor does not work
ii Motor function and overload relay trips
iii Motor function but only partially functional control circuit
Methods of detecting damage
Among the known methods necessary to detect damage are as follows
1 Turn off the electricity at the main switch (main switch) in order to avoid any danger during the
work carried out to detect damage
2 Check all the protective gear that controls the motor control main circuit
11 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
3 Make sure the damage function control circuit
4 Check the control circuit according to the schematic circuit diagram of the motor control
5 Check the operation of the control circuit
Note
Use wiring that has been installed on the SYSTEM OF MOTOR CONTROL BOARD by Forward
Reverse control circuit for Star Delta to test and look for damage
SELF-ASSESSMENT QUESTIONS
1 (a) Explain what is meant by the term lsquoback emfrsquo in a motor
(b) Outline the basic differences between series shunt and compound wound dc motors
2 (a) With the aid of diagrams explain how the speed of series shunt and compound-wound motors
may be controlled
(b) A 440V dc shunt-wound motor has a field resistance of 200R and an armature resistance of 06 R
When its speed is 20 rev d second the current drawn from the supply is 122A Calculate its back
emf at this speed If the speed were decreased to 19 revssecond the field flux remaining unchanged
calculate the new back emf and the new armature current
3 A load of 64 kW at 240 V is supplied from the terminals of a shunt-wound dc generator The field
resistance is 180 A Calculate the armature current
4 (a) Explain with the aid of a diagram how a rotating magnetic field may be
(b) What is meant by lsquosynchronous speedrsquo
Calculate the synchronous obtained speed of a 12 pole motor if the supply frequency is 50Hz
5 (a) Explain the action of a synchronous motor
(b) What methods are available to start a synchronous motor Explain with diagrams
6 (a) Explain the action of a cage induction motor
(b) What is meant by the term lsquosliprsquo
Calculate the percentage slip of a six pole induction motor running at 162 revssecond from a 50 Hz
supply
7 Describe with sketches three different ways of starting a single-phase induction motor
12 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
8 Explain with the aid of a sketch the action of a three-phase DOL starter
What are dashpots used for How are remote start and stop buttons connected
9 A I0 kW 240V 50Hz single-phase cage rotor induction motor is 85efficient and has a PF of 068
lagging Calculate the motor current and the value of capacitor required to raise the PF to 093
lagging
10 Calculate the torque developed by an 18 kW four-pole induction motor run at 35 slip from a
50Hz supply
APPENDIX 1
13 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 11
14 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 111
Attachment Reference
httpswwwtlc-directcoukBook621htm
httpwwwstgovmyindexphpms
15 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
iii Live and Neutral Conductor Continuity Test
a) Protection Conductor Continuity Test
bull To ascertain that all protection conductors are connected in the correct and effective manner
bull Test equipment ndash Multimeter (Ohm range) or Ohm meter
bull Test Method
1 1048766 Ensure that the main switch RCD and MCB are open circuited (switched off) and all loads are
disconnected
2 1048766 Connected the test leads as in the Figure 81
3 1048766 The meter reading shall be less than 1 Ω
Final Ring Circuit Conductor Continuity Test
bull To ensure that all conductors around the ring circuit have continuity
bull Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
bull Test Method
1 1048766 Disconnect both the supply source live conductors from the MCB the neutral conductor
from the neutral terminals and the earth conductor from the earth terminal in the distribution
fuse box
2 1048766 Connect the test leads as in the Figure 82 (EE)
3 1048766 Repeat the procedure for (L-L) and (N-N)
4 1048766 The meter reading value shall be less than 1 ohm Figure 82 - Final Ring Circuit Conductor
Continuity Test Ohm Meter
Disconnect both the supply source cables from mcbfuse
Take readings at earth conductors of both sources and note resistance readings
Live and Neutral Conductor Continuity Test
1 To ensure that each conductor in the circuit has continuity
2 Test Equipment ndash Multimeter (Ohm range) or Ohm Meter
3 Test Method
1 1048766 Switch off the Main switch RCD and MCB
2 1048766 Disconnect all loads
3 1048766 Switch on all switches in the circuit
4 1048766 Disconnect the fusesfinal circuit breakers and close the circuit
5 1048766 Carry out the test as shown in Figure 83
6 1048766 The meter reading value shall be less than 1 ohm Figure 83 - Live and Neutral
Conductor Continuity Test Ohm Meter
Insulation Resistance Test
69 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
i Ensure that there is no leakage current between phase conductors phase and neutral conductors and
phase conductor and earth
ii Test the strength of the cable insulation
iii Test Equipment ndash Insulation Resistance Tester Operating voltage is 250VDC or 500VDC
iv Test Method
1 1048766 Switch off main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in the Table below
5 1048766 Meter reading value shall be less than 1 Megaohm
Polarity Test
i Ensure that each fuse or single pole control and protection device is connected only in the phase
conductor
ii Intermediate contact of Edison screw lamp holder is connected to the phase conductor
iii Ensure that phase neutral and earth conductors at socket outlets are connected at the correct
terminals
iv Test Equipment ndash Multimeter (Ohm range) or Ohm meter
v Test Method
1 1048766 Switch off Main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in Figure 85
5 1048766 Test switches and single phase control devices at the phase conductors
6 1048766 Test socket outlet connection sources
7 1048766 Test Edison screw lamp holder connections
8 1048766 Meter reading value shall be less than 1 Ω
Earth Electrode Resistance Test
i To test the earth electrode resistance
70 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
ii To ascertain the suitability of the location of the electrode
iii To ensure that the electrode is not buried within the resistance area of another electrode
iv Test equipment ndash Earth Resistance Tester
v Test method -
1 1048766 Terminal rsquoErsquo is connected to the electrode to be tested (green conductor)
2 1048766 Terminal lsquoPrsquo is connected to the potential spike (yellow conductor) at a distance of 10
meters from the earth electrode
3 1048766 Terminal lsquoCrsquo is connected to the current spike (red conductor) at a distance of 20 meters
from the earth electrode E P C Electrode 10 meter 10 meter
Figure 86 ndash Earth Electrode Resistance Measurement Test Equipment
Earth Electrode Resistance Measurement Method (Figure 86)
This test must be repeated at least three times to ensure that the reading is not affected by interacting
earthing regions
i Record the first reading (Z1) Example Z1 = 10 Ω
ii Move the voltage spike to a distance of 6 meters from the original position Record the second
reading (Z2) Example Z2 = 10 Ω
iii Move the voltage spike to a distance of 6 meters from the original position Record the third
reading (Z3)
Example Z3 = 10 Ω
Residual Current Device Test
71 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
i Ensure that the residual current device (RCD) trips within the set time on the occurrence of current
leakage to earth
ii Test Equipment ndash RCD Tester RCCB Tester
iii Test Method 1
1 1048766 Use the Trip Test Button
2 1048766 Press the trip button found on the RCD to determine if it trips or otherwise This test would
not be able to determine the sensitivity of the RCD nor the time taken for it to trip
iv Test Method 2
1048766 Use a RCD Tester
This equipment is equipped with a 13A plug which can be connected to a 13A socket outlet Select the
RCD sensitivity to be the same as the sensitivity of the RCD to be tested to determine if the RCD can
trip The time to trip shall not exceed 40 mS
1048766 Test method ndash
a) Position the selection switch in accordance with the sensitivity of the RCD used
Example 100 mA 01 A
b) Position the operations switch to lsquoNo Triprsquo (frac12 Rated mA = 50) connect the 3 pin plug to
the 13A socket outlet
c) Switch on the 13A socket outlet ndash ensure that the P-N and P-E lights light up This shows that
the polarity is correct (Note if both the lights as above do not light up the test cannot be
continued)
d) Press the test button ndash the reading shows less than 200 millisecond and simultaneously the
lsquotestrsquo light lights up and the P-N and P-E lights do not light up At that instant the RCD will
not trip
e) Move the selection switch to 180o (+ve wave) ndash repeat steps (d) and (e) = 100)
f) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
g) Move the selection switch to 0o (-ve wave)
h) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
i) The above test is repeated until a near correct reading is obtained
j) Record the test results
k) Change the operations switch to lsquoFast Triprsquo and press the test button ndash RCD will trip within a
time not exceeding 40 mS
l) Repeat a number of times at 0o or 180o
72 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 9 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (DC)
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
73 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Start stop button 240Vac 5A 2
9 Filament lamp (Bulb ) 240Vac 40W 3
10 Overload Relay 415V 20A 3
11 Three phase induction motor 5 hp 3
12 Single phase step down transformer 2500VA 1
13 Single core PVC insulated Cable 1mm 2 As required
14 Single core PVC insulated Cable 25mm 2 As required
15 DIN rail 35 mm As required
16 PVC type Cable tray 50 mm x 50 mm As required
17 Cable ties 4 ldquo As required
18 Flexible wires 05 mm As required
19 PVC Connectors 5 A amp 20 A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the schematic
diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a optional exercise
i Simple DOL starter
ii Forward reverse DOL starter
iii Forward Reverse Dahlander motor
iv Three motors operated in sequence by DOL starter operated by manual push
button or time delay relay
74 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
a One loop per-cycle
b Continuous operation in a loop
c optional circuit design to represent the same task
v Only one out of three motors to be operated at a time (quiz)
4 Test the functionality of completed project
LESSON 10 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (AC)
75 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 1
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Lamp point 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
76 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
11 Overload Relay 415V 20A 3
12 Three phase induction
motor
5 hp 3
13 Single core PVC insulated
Cable
1mm 2 As required
14 Single core PVC insulated
Cable
25mm 2 As required
15 DIN rail 35 mm As required
16 PVC type Cable tray 50 mm x 50 mm As required
17 Cable ties 4 ldquo As required
18 Flexible wires 05 mm As required
19 PVC Connectors 5 A amp 20 A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the
schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram optional exercise
4 Simple DOL starter
5 Forward reverse DOL starter
6 Test the functionality of completed project
77 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 1
78 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
cm
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Indicating light 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
11 Overload Relay 415V 20A 3
12 Three phase induction motor 5 hp 3
13 Single phase step down
transformer
2500VA 1
14 Single core PVC insulated
Cable
1mm 2 As required
15 Single core PVC insulated
Cable
25mm 2 As required
16 DIN rail 35 mm As required
17 PVC type Cable tray 50 mm x 50 mm As required
18 Cable ties 4 ldquo As required
19 Flexible wires 05 mm As required
20 PVC Connectors 5 A amp 20 A 240 V As required
21 Single pole MCB 6A 240 V 1
22 Single pole MCB 2A 240 V 1
23 Triple pole MCB 20A 415 V 1
24 Mounting board 30 cm x 40 cm x 3
cm
1
25 Relay cw 11 pin socket 10 A 240 Vac 2
26 Time delay relay 10 A 240 Vac 3
27 Triple pole Contactor 20A 240Vac 3
28 Batten type Lamp holder 240Vac 10 A 3
29 Start stop button 240Vac 10A 2
30 Indicating light (Bulb ) 240Vac 25W 3
31 Overload Relay 415V 20A 1
32 Three phase dahlander type
induction motor
5 hp 1
33 Single phase step down
transformer
24024Vac
2500VA
1
79 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
34 Single core PVC insulated
Cable
1mm 2 As required
35 Single core PVC insulated
Cable
25mm 2 As required
36 DIN rail 35 mm As required
37 PVC type Cable tray 50 mm x 50 mm As required
38 Cable ties 4 ldquo As required
39 Flexible wires 075 mm As required
40 PVC Connectors 5 A amp 20 A 240 V As required
41 Terminal block 20A 240Vac As required
Procedures
5 Identify each component according to specification and quantity required from the schematic
diagram attached
6 Test the functionality of each component by using multi-meter or power supply whichever
applicable
7 Wire component according to circuit diagram
8 Three motors operated in sequence by DOL starter operated by manual push button or time
delay relay
a One loop per-cycle
b Continuous operation in a loop
c optional circuit design to represent the same task
d Only one out of three motors to be operated at a time (quiz)
9 Test the functionality of completed project
80 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
BASIC DESIGN INDUSTRIAL MOTOR CONTROL (SEQUENCE CONTROL)
THREE PHASE INDUCTION MOTOR OPERATED IN SEQUENCE BY DIRECT ON LINE
STARTER
LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
81 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
82 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Lcd lamp indicator 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
11 Overload Relay 415V 20A 3
12 Three phase induction motor 5 hp 3
13 Single phase step down transformer 2500VA 1
14 Single core PVC insulated Cable 1mm 2 As required
15 Single core PVC insulated Cable 25mm 2 As required
16 DIN rail 35 mm As required
17 PVC type Cable tray 50 mm x 50 mm As required
18 Cable ties 4 ldquo As required
19 Flexible wires 1 mm Oslash As required
20 PVC Terminal block 10A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the schematic
diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a optional exercise
i Forward Reverse dahlander motor
4 Test the functionality of completed project
83 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
THREE PHASE DAHLANDER TYPE INDUCTION MOTOR OPERATED FORWARD AND
REVERSE OPERATION BY DIRECT ON LINE STARTER
84 ndash 99EASYTECH ENTERPRISE
LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
Introduction
If a motors windings are connected in the star configuration any two phases will be in series across
the supply and hence the line current will be smaller(by 577) than if the windings were connected in
the delta arrangement
Hence larger-type motors with heavy starting currents are first connected in star and then when the
starting currents fall in delta This of course means that all six of the ends of the windings must be
brought to terminations outside the casing (Fig 833)
EZTECH
EZTECH ELECTRICAL INSTALLATION GUIDE
The automatic version of this starter incorporates a timing relay which automatically changes the
connections from star to delta Figs 834 and 835 show the wiring and schematic diagrams for a star
delta starter
Objectives
1 Identify component and the specification
2 Design forward reverse star delta starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
2 ndash 99EASYTECH ENTERPRISE
REV -C
LEGENDMCCB Moulded Case Circuit BreakerTOR Thermal Over Load RelayFOW-C Mains Forward ContactorREV-C Mains Reverse ContactorDC Delta ContactorSC Star ContactorS-SW Mains Selector Switch
SC
V2
W2
U2
DC
V1
W1
U1
TOR
TOR
FOW-C
30A MCCB
TOR
MAIN CIRCUIT FORWARD REVERSE STAR DELTA
RYBN S
-SW
3 PHASEINDUCTION MOTOR
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Relay 10 A 240V 3
5 Triple pole Contactor
6 cw NO NC auxiliary contact
240Vac 20 A 4
7 Overload Relay 415 V 1
8 LED indicator 240vac 5 A 4
9 Start stop button 240Vac 5A 2
10 DIN rail 35 mm As required
11 Flexible wires 1 mm As required
12 Single core PVC insulated
wire
25 mm As required
13 Terminal block 20 A As required
14 Squirrel cage motor 5kW 1
15 5 pin plug and socket 415V 20A 1
16 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
3 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
a Manual star delta
b Manual Forward reverse star delta starter
c Automatic star delta starter
d Automatic Forward reverse star delta starter
4 Test the functionality of completed project
4 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
Objectives
1 Identify component and the specification
2 Design auto transformer starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
5 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Autotransformer starter is used to start a 3 phase induction motor that has a rating between 10 to 15 hp
6 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Autotransformer set 10Kw 415 V 50 Hz 1
5 Triple pole Contactor 240Vac 4
6 Batten type Lamp holder 240 Vac 105 A 4
7 Start stop button 240Vac 10A 4
8 Filament lamp (Bulb ) 240Vac 40W 4
9 DIN rail 35 mm As required
10 Flexible wires 1 mm As required
7 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
11 Single core PVC insulated
wire
25 mm As required
12 Terminal block 20 A As required
13 Squirrel cage motor 10kW 1
14 5 pin plug and socket 415V 20A 1
15 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a open transient autotransformer starter
b close transient autotransformer starter
c Forward reverse autotransformer starter
4 Test the functionality of completed project
8 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
Objectives
1 Identify component and the specification
2 Design rotor resistance starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
9 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Rotor Resistor set 10kW 1
5 Triple pole Contactor 240Vac 20A 4
6 Indicating light 240vac 5 A 4
7 Start stop push button 240Vac 5A 4
8 DIN rail 35 mm As required
9 Flexible wires 1 mm 2 As required
10 Single core PVC insulated wire 25 mm 2 As required
11 Terminal block 20 A As required
12 Slip Ring motor 10kW 1
13 5 pin round 3 phase socket 415V 20A 1
14 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
10 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
4 Test the functionality of completed project
a Dead circuit test b Life circuit test
5 Measure starting and running Amps
LESSON 16
TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
An installation in general will suffer damage
Damage usually occurs on the electric motor control as follows
1 Damage to the main circuit
2 Damage to the control circuit
The cause of the damage
i Overcurrent overload short circuit
ii Leakage current to ground
iii Equipment malfunction
iv The main control circuit
a Trip of main circuit protection devices fire
b Defect of motor terminal such as short circuit fire loose
v The control circuit is not functioning -
a contactor relay relay time overload relay does not work damaged burned
b Loose cable connection disconnected
Detecting and Repairing Damage
Examples of damage are as follows
i Motor does not work
ii Motor function and overload relay trips
iii Motor function but only partially functional control circuit
Methods of detecting damage
Among the known methods necessary to detect damage are as follows
1 Turn off the electricity at the main switch (main switch) in order to avoid any danger during the
work carried out to detect damage
2 Check all the protective gear that controls the motor control main circuit
11 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
3 Make sure the damage function control circuit
4 Check the control circuit according to the schematic circuit diagram of the motor control
5 Check the operation of the control circuit
Note
Use wiring that has been installed on the SYSTEM OF MOTOR CONTROL BOARD by Forward
Reverse control circuit for Star Delta to test and look for damage
SELF-ASSESSMENT QUESTIONS
1 (a) Explain what is meant by the term lsquoback emfrsquo in a motor
(b) Outline the basic differences between series shunt and compound wound dc motors
2 (a) With the aid of diagrams explain how the speed of series shunt and compound-wound motors
may be controlled
(b) A 440V dc shunt-wound motor has a field resistance of 200R and an armature resistance of 06 R
When its speed is 20 rev d second the current drawn from the supply is 122A Calculate its back
emf at this speed If the speed were decreased to 19 revssecond the field flux remaining unchanged
calculate the new back emf and the new armature current
3 A load of 64 kW at 240 V is supplied from the terminals of a shunt-wound dc generator The field
resistance is 180 A Calculate the armature current
4 (a) Explain with the aid of a diagram how a rotating magnetic field may be
(b) What is meant by lsquosynchronous speedrsquo
Calculate the synchronous obtained speed of a 12 pole motor if the supply frequency is 50Hz
5 (a) Explain the action of a synchronous motor
(b) What methods are available to start a synchronous motor Explain with diagrams
6 (a) Explain the action of a cage induction motor
(b) What is meant by the term lsquosliprsquo
Calculate the percentage slip of a six pole induction motor running at 162 revssecond from a 50 Hz
supply
7 Describe with sketches three different ways of starting a single-phase induction motor
12 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
8 Explain with the aid of a sketch the action of a three-phase DOL starter
What are dashpots used for How are remote start and stop buttons connected
9 A I0 kW 240V 50Hz single-phase cage rotor induction motor is 85efficient and has a PF of 068
lagging Calculate the motor current and the value of capacitor required to raise the PF to 093
lagging
10 Calculate the torque developed by an 18 kW four-pole induction motor run at 35 slip from a
50Hz supply
APPENDIX 1
13 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 11
14 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 111
Attachment Reference
httpswwwtlc-directcoukBook621htm
httpwwwstgovmyindexphpms
15 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
i Ensure that there is no leakage current between phase conductors phase and neutral conductors and
phase conductor and earth
ii Test the strength of the cable insulation
iii Test Equipment ndash Insulation Resistance Tester Operating voltage is 250VDC or 500VDC
iv Test Method
1 1048766 Switch off main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in the Table below
5 1048766 Meter reading value shall be less than 1 Megaohm
Polarity Test
i Ensure that each fuse or single pole control and protection device is connected only in the phase
conductor
ii Intermediate contact of Edison screw lamp holder is connected to the phase conductor
iii Ensure that phase neutral and earth conductors at socket outlets are connected at the correct
terminals
iv Test Equipment ndash Multimeter (Ohm range) or Ohm meter
v Test Method
1 1048766 Switch off Main switch
2 1048766 Disconnect all loads
3 1048766 Switch on all circuit control switches
4 1048766 Carry out test as in Figure 85
5 1048766 Test switches and single phase control devices at the phase conductors
6 1048766 Test socket outlet connection sources
7 1048766 Test Edison screw lamp holder connections
8 1048766 Meter reading value shall be less than 1 Ω
Earth Electrode Resistance Test
i To test the earth electrode resistance
70 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
ii To ascertain the suitability of the location of the electrode
iii To ensure that the electrode is not buried within the resistance area of another electrode
iv Test equipment ndash Earth Resistance Tester
v Test method -
1 1048766 Terminal rsquoErsquo is connected to the electrode to be tested (green conductor)
2 1048766 Terminal lsquoPrsquo is connected to the potential spike (yellow conductor) at a distance of 10
meters from the earth electrode
3 1048766 Terminal lsquoCrsquo is connected to the current spike (red conductor) at a distance of 20 meters
from the earth electrode E P C Electrode 10 meter 10 meter
Figure 86 ndash Earth Electrode Resistance Measurement Test Equipment
Earth Electrode Resistance Measurement Method (Figure 86)
This test must be repeated at least three times to ensure that the reading is not affected by interacting
earthing regions
i Record the first reading (Z1) Example Z1 = 10 Ω
ii Move the voltage spike to a distance of 6 meters from the original position Record the second
reading (Z2) Example Z2 = 10 Ω
iii Move the voltage spike to a distance of 6 meters from the original position Record the third
reading (Z3)
Example Z3 = 10 Ω
Residual Current Device Test
71 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
i Ensure that the residual current device (RCD) trips within the set time on the occurrence of current
leakage to earth
ii Test Equipment ndash RCD Tester RCCB Tester
iii Test Method 1
1 1048766 Use the Trip Test Button
2 1048766 Press the trip button found on the RCD to determine if it trips or otherwise This test would
not be able to determine the sensitivity of the RCD nor the time taken for it to trip
iv Test Method 2
1048766 Use a RCD Tester
This equipment is equipped with a 13A plug which can be connected to a 13A socket outlet Select the
RCD sensitivity to be the same as the sensitivity of the RCD to be tested to determine if the RCD can
trip The time to trip shall not exceed 40 mS
1048766 Test method ndash
a) Position the selection switch in accordance with the sensitivity of the RCD used
Example 100 mA 01 A
b) Position the operations switch to lsquoNo Triprsquo (frac12 Rated mA = 50) connect the 3 pin plug to
the 13A socket outlet
c) Switch on the 13A socket outlet ndash ensure that the P-N and P-E lights light up This shows that
the polarity is correct (Note if both the lights as above do not light up the test cannot be
continued)
d) Press the test button ndash the reading shows less than 200 millisecond and simultaneously the
lsquotestrsquo light lights up and the P-N and P-E lights do not light up At that instant the RCD will
not trip
e) Move the selection switch to 180o (+ve wave) ndash repeat steps (d) and (e) = 100)
f) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
g) Move the selection switch to 0o (-ve wave)
h) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
i) The above test is repeated until a near correct reading is obtained
j) Record the test results
k) Change the operations switch to lsquoFast Triprsquo and press the test button ndash RCD will trip within a
time not exceeding 40 mS
l) Repeat a number of times at 0o or 180o
72 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 9 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (DC)
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
73 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Start stop button 240Vac 5A 2
9 Filament lamp (Bulb ) 240Vac 40W 3
10 Overload Relay 415V 20A 3
11 Three phase induction motor 5 hp 3
12 Single phase step down transformer 2500VA 1
13 Single core PVC insulated Cable 1mm 2 As required
14 Single core PVC insulated Cable 25mm 2 As required
15 DIN rail 35 mm As required
16 PVC type Cable tray 50 mm x 50 mm As required
17 Cable ties 4 ldquo As required
18 Flexible wires 05 mm As required
19 PVC Connectors 5 A amp 20 A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the schematic
diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a optional exercise
i Simple DOL starter
ii Forward reverse DOL starter
iii Forward Reverse Dahlander motor
iv Three motors operated in sequence by DOL starter operated by manual push
button or time delay relay
74 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
a One loop per-cycle
b Continuous operation in a loop
c optional circuit design to represent the same task
v Only one out of three motors to be operated at a time (quiz)
4 Test the functionality of completed project
LESSON 10 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (AC)
75 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 1
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Lamp point 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
76 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
11 Overload Relay 415V 20A 3
12 Three phase induction
motor
5 hp 3
13 Single core PVC insulated
Cable
1mm 2 As required
14 Single core PVC insulated
Cable
25mm 2 As required
15 DIN rail 35 mm As required
16 PVC type Cable tray 50 mm x 50 mm As required
17 Cable ties 4 ldquo As required
18 Flexible wires 05 mm As required
19 PVC Connectors 5 A amp 20 A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the
schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram optional exercise
4 Simple DOL starter
5 Forward reverse DOL starter
6 Test the functionality of completed project
77 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 1
78 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
cm
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Indicating light 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
11 Overload Relay 415V 20A 3
12 Three phase induction motor 5 hp 3
13 Single phase step down
transformer
2500VA 1
14 Single core PVC insulated
Cable
1mm 2 As required
15 Single core PVC insulated
Cable
25mm 2 As required
16 DIN rail 35 mm As required
17 PVC type Cable tray 50 mm x 50 mm As required
18 Cable ties 4 ldquo As required
19 Flexible wires 05 mm As required
20 PVC Connectors 5 A amp 20 A 240 V As required
21 Single pole MCB 6A 240 V 1
22 Single pole MCB 2A 240 V 1
23 Triple pole MCB 20A 415 V 1
24 Mounting board 30 cm x 40 cm x 3
cm
1
25 Relay cw 11 pin socket 10 A 240 Vac 2
26 Time delay relay 10 A 240 Vac 3
27 Triple pole Contactor 20A 240Vac 3
28 Batten type Lamp holder 240Vac 10 A 3
29 Start stop button 240Vac 10A 2
30 Indicating light (Bulb ) 240Vac 25W 3
31 Overload Relay 415V 20A 1
32 Three phase dahlander type
induction motor
5 hp 1
33 Single phase step down
transformer
24024Vac
2500VA
1
79 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
34 Single core PVC insulated
Cable
1mm 2 As required
35 Single core PVC insulated
Cable
25mm 2 As required
36 DIN rail 35 mm As required
37 PVC type Cable tray 50 mm x 50 mm As required
38 Cable ties 4 ldquo As required
39 Flexible wires 075 mm As required
40 PVC Connectors 5 A amp 20 A 240 V As required
41 Terminal block 20A 240Vac As required
Procedures
5 Identify each component according to specification and quantity required from the schematic
diagram attached
6 Test the functionality of each component by using multi-meter or power supply whichever
applicable
7 Wire component according to circuit diagram
8 Three motors operated in sequence by DOL starter operated by manual push button or time
delay relay
a One loop per-cycle
b Continuous operation in a loop
c optional circuit design to represent the same task
d Only one out of three motors to be operated at a time (quiz)
9 Test the functionality of completed project
80 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
BASIC DESIGN INDUSTRIAL MOTOR CONTROL (SEQUENCE CONTROL)
THREE PHASE INDUCTION MOTOR OPERATED IN SEQUENCE BY DIRECT ON LINE
STARTER
LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
81 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
82 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Lcd lamp indicator 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
11 Overload Relay 415V 20A 3
12 Three phase induction motor 5 hp 3
13 Single phase step down transformer 2500VA 1
14 Single core PVC insulated Cable 1mm 2 As required
15 Single core PVC insulated Cable 25mm 2 As required
16 DIN rail 35 mm As required
17 PVC type Cable tray 50 mm x 50 mm As required
18 Cable ties 4 ldquo As required
19 Flexible wires 1 mm Oslash As required
20 PVC Terminal block 10A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the schematic
diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a optional exercise
i Forward Reverse dahlander motor
4 Test the functionality of completed project
83 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
THREE PHASE DAHLANDER TYPE INDUCTION MOTOR OPERATED FORWARD AND
REVERSE OPERATION BY DIRECT ON LINE STARTER
84 ndash 99EASYTECH ENTERPRISE
LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
Introduction
If a motors windings are connected in the star configuration any two phases will be in series across
the supply and hence the line current will be smaller(by 577) than if the windings were connected in
the delta arrangement
Hence larger-type motors with heavy starting currents are first connected in star and then when the
starting currents fall in delta This of course means that all six of the ends of the windings must be
brought to terminations outside the casing (Fig 833)
EZTECH
EZTECH ELECTRICAL INSTALLATION GUIDE
The automatic version of this starter incorporates a timing relay which automatically changes the
connections from star to delta Figs 834 and 835 show the wiring and schematic diagrams for a star
delta starter
Objectives
1 Identify component and the specification
2 Design forward reverse star delta starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
2 ndash 99EASYTECH ENTERPRISE
REV -C
LEGENDMCCB Moulded Case Circuit BreakerTOR Thermal Over Load RelayFOW-C Mains Forward ContactorREV-C Mains Reverse ContactorDC Delta ContactorSC Star ContactorS-SW Mains Selector Switch
SC
V2
W2
U2
DC
V1
W1
U1
TOR
TOR
FOW-C
30A MCCB
TOR
MAIN CIRCUIT FORWARD REVERSE STAR DELTA
RYBN S
-SW
3 PHASEINDUCTION MOTOR
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Relay 10 A 240V 3
5 Triple pole Contactor
6 cw NO NC auxiliary contact
240Vac 20 A 4
7 Overload Relay 415 V 1
8 LED indicator 240vac 5 A 4
9 Start stop button 240Vac 5A 2
10 DIN rail 35 mm As required
11 Flexible wires 1 mm As required
12 Single core PVC insulated
wire
25 mm As required
13 Terminal block 20 A As required
14 Squirrel cage motor 5kW 1
15 5 pin plug and socket 415V 20A 1
16 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
3 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
a Manual star delta
b Manual Forward reverse star delta starter
c Automatic star delta starter
d Automatic Forward reverse star delta starter
4 Test the functionality of completed project
4 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
Objectives
1 Identify component and the specification
2 Design auto transformer starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
5 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Autotransformer starter is used to start a 3 phase induction motor that has a rating between 10 to 15 hp
6 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Autotransformer set 10Kw 415 V 50 Hz 1
5 Triple pole Contactor 240Vac 4
6 Batten type Lamp holder 240 Vac 105 A 4
7 Start stop button 240Vac 10A 4
8 Filament lamp (Bulb ) 240Vac 40W 4
9 DIN rail 35 mm As required
10 Flexible wires 1 mm As required
7 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
11 Single core PVC insulated
wire
25 mm As required
12 Terminal block 20 A As required
13 Squirrel cage motor 10kW 1
14 5 pin plug and socket 415V 20A 1
15 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a open transient autotransformer starter
b close transient autotransformer starter
c Forward reverse autotransformer starter
4 Test the functionality of completed project
8 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
Objectives
1 Identify component and the specification
2 Design rotor resistance starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
9 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Rotor Resistor set 10kW 1
5 Triple pole Contactor 240Vac 20A 4
6 Indicating light 240vac 5 A 4
7 Start stop push button 240Vac 5A 4
8 DIN rail 35 mm As required
9 Flexible wires 1 mm 2 As required
10 Single core PVC insulated wire 25 mm 2 As required
11 Terminal block 20 A As required
12 Slip Ring motor 10kW 1
13 5 pin round 3 phase socket 415V 20A 1
14 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
10 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
4 Test the functionality of completed project
a Dead circuit test b Life circuit test
5 Measure starting and running Amps
LESSON 16
TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
An installation in general will suffer damage
Damage usually occurs on the electric motor control as follows
1 Damage to the main circuit
2 Damage to the control circuit
The cause of the damage
i Overcurrent overload short circuit
ii Leakage current to ground
iii Equipment malfunction
iv The main control circuit
a Trip of main circuit protection devices fire
b Defect of motor terminal such as short circuit fire loose
v The control circuit is not functioning -
a contactor relay relay time overload relay does not work damaged burned
b Loose cable connection disconnected
Detecting and Repairing Damage
Examples of damage are as follows
i Motor does not work
ii Motor function and overload relay trips
iii Motor function but only partially functional control circuit
Methods of detecting damage
Among the known methods necessary to detect damage are as follows
1 Turn off the electricity at the main switch (main switch) in order to avoid any danger during the
work carried out to detect damage
2 Check all the protective gear that controls the motor control main circuit
11 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
3 Make sure the damage function control circuit
4 Check the control circuit according to the schematic circuit diagram of the motor control
5 Check the operation of the control circuit
Note
Use wiring that has been installed on the SYSTEM OF MOTOR CONTROL BOARD by Forward
Reverse control circuit for Star Delta to test and look for damage
SELF-ASSESSMENT QUESTIONS
1 (a) Explain what is meant by the term lsquoback emfrsquo in a motor
(b) Outline the basic differences between series shunt and compound wound dc motors
2 (a) With the aid of diagrams explain how the speed of series shunt and compound-wound motors
may be controlled
(b) A 440V dc shunt-wound motor has a field resistance of 200R and an armature resistance of 06 R
When its speed is 20 rev d second the current drawn from the supply is 122A Calculate its back
emf at this speed If the speed were decreased to 19 revssecond the field flux remaining unchanged
calculate the new back emf and the new armature current
3 A load of 64 kW at 240 V is supplied from the terminals of a shunt-wound dc generator The field
resistance is 180 A Calculate the armature current
4 (a) Explain with the aid of a diagram how a rotating magnetic field may be
(b) What is meant by lsquosynchronous speedrsquo
Calculate the synchronous obtained speed of a 12 pole motor if the supply frequency is 50Hz
5 (a) Explain the action of a synchronous motor
(b) What methods are available to start a synchronous motor Explain with diagrams
6 (a) Explain the action of a cage induction motor
(b) What is meant by the term lsquosliprsquo
Calculate the percentage slip of a six pole induction motor running at 162 revssecond from a 50 Hz
supply
7 Describe with sketches three different ways of starting a single-phase induction motor
12 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
8 Explain with the aid of a sketch the action of a three-phase DOL starter
What are dashpots used for How are remote start and stop buttons connected
9 A I0 kW 240V 50Hz single-phase cage rotor induction motor is 85efficient and has a PF of 068
lagging Calculate the motor current and the value of capacitor required to raise the PF to 093
lagging
10 Calculate the torque developed by an 18 kW four-pole induction motor run at 35 slip from a
50Hz supply
APPENDIX 1
13 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 11
14 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 111
Attachment Reference
httpswwwtlc-directcoukBook621htm
httpwwwstgovmyindexphpms
15 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
ii To ascertain the suitability of the location of the electrode
iii To ensure that the electrode is not buried within the resistance area of another electrode
iv Test equipment ndash Earth Resistance Tester
v Test method -
1 1048766 Terminal rsquoErsquo is connected to the electrode to be tested (green conductor)
2 1048766 Terminal lsquoPrsquo is connected to the potential spike (yellow conductor) at a distance of 10
meters from the earth electrode
3 1048766 Terminal lsquoCrsquo is connected to the current spike (red conductor) at a distance of 20 meters
from the earth electrode E P C Electrode 10 meter 10 meter
Figure 86 ndash Earth Electrode Resistance Measurement Test Equipment
Earth Electrode Resistance Measurement Method (Figure 86)
This test must be repeated at least three times to ensure that the reading is not affected by interacting
earthing regions
i Record the first reading (Z1) Example Z1 = 10 Ω
ii Move the voltage spike to a distance of 6 meters from the original position Record the second
reading (Z2) Example Z2 = 10 Ω
iii Move the voltage spike to a distance of 6 meters from the original position Record the third
reading (Z3)
Example Z3 = 10 Ω
Residual Current Device Test
71 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
i Ensure that the residual current device (RCD) trips within the set time on the occurrence of current
leakage to earth
ii Test Equipment ndash RCD Tester RCCB Tester
iii Test Method 1
1 1048766 Use the Trip Test Button
2 1048766 Press the trip button found on the RCD to determine if it trips or otherwise This test would
not be able to determine the sensitivity of the RCD nor the time taken for it to trip
iv Test Method 2
1048766 Use a RCD Tester
This equipment is equipped with a 13A plug which can be connected to a 13A socket outlet Select the
RCD sensitivity to be the same as the sensitivity of the RCD to be tested to determine if the RCD can
trip The time to trip shall not exceed 40 mS
1048766 Test method ndash
a) Position the selection switch in accordance with the sensitivity of the RCD used
Example 100 mA 01 A
b) Position the operations switch to lsquoNo Triprsquo (frac12 Rated mA = 50) connect the 3 pin plug to
the 13A socket outlet
c) Switch on the 13A socket outlet ndash ensure that the P-N and P-E lights light up This shows that
the polarity is correct (Note if both the lights as above do not light up the test cannot be
continued)
d) Press the test button ndash the reading shows less than 200 millisecond and simultaneously the
lsquotestrsquo light lights up and the P-N and P-E lights do not light up At that instant the RCD will
not trip
e) Move the selection switch to 180o (+ve wave) ndash repeat steps (d) and (e) = 100)
f) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
g) Move the selection switch to 0o (-ve wave)
h) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
i) The above test is repeated until a near correct reading is obtained
j) Record the test results
k) Change the operations switch to lsquoFast Triprsquo and press the test button ndash RCD will trip within a
time not exceeding 40 mS
l) Repeat a number of times at 0o or 180o
72 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 9 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (DC)
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
73 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Start stop button 240Vac 5A 2
9 Filament lamp (Bulb ) 240Vac 40W 3
10 Overload Relay 415V 20A 3
11 Three phase induction motor 5 hp 3
12 Single phase step down transformer 2500VA 1
13 Single core PVC insulated Cable 1mm 2 As required
14 Single core PVC insulated Cable 25mm 2 As required
15 DIN rail 35 mm As required
16 PVC type Cable tray 50 mm x 50 mm As required
17 Cable ties 4 ldquo As required
18 Flexible wires 05 mm As required
19 PVC Connectors 5 A amp 20 A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the schematic
diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a optional exercise
i Simple DOL starter
ii Forward reverse DOL starter
iii Forward Reverse Dahlander motor
iv Three motors operated in sequence by DOL starter operated by manual push
button or time delay relay
74 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
a One loop per-cycle
b Continuous operation in a loop
c optional circuit design to represent the same task
v Only one out of three motors to be operated at a time (quiz)
4 Test the functionality of completed project
LESSON 10 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (AC)
75 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 1
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Lamp point 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
76 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
11 Overload Relay 415V 20A 3
12 Three phase induction
motor
5 hp 3
13 Single core PVC insulated
Cable
1mm 2 As required
14 Single core PVC insulated
Cable
25mm 2 As required
15 DIN rail 35 mm As required
16 PVC type Cable tray 50 mm x 50 mm As required
17 Cable ties 4 ldquo As required
18 Flexible wires 05 mm As required
19 PVC Connectors 5 A amp 20 A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the
schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram optional exercise
4 Simple DOL starter
5 Forward reverse DOL starter
6 Test the functionality of completed project
77 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 1
78 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
cm
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Indicating light 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
11 Overload Relay 415V 20A 3
12 Three phase induction motor 5 hp 3
13 Single phase step down
transformer
2500VA 1
14 Single core PVC insulated
Cable
1mm 2 As required
15 Single core PVC insulated
Cable
25mm 2 As required
16 DIN rail 35 mm As required
17 PVC type Cable tray 50 mm x 50 mm As required
18 Cable ties 4 ldquo As required
19 Flexible wires 05 mm As required
20 PVC Connectors 5 A amp 20 A 240 V As required
21 Single pole MCB 6A 240 V 1
22 Single pole MCB 2A 240 V 1
23 Triple pole MCB 20A 415 V 1
24 Mounting board 30 cm x 40 cm x 3
cm
1
25 Relay cw 11 pin socket 10 A 240 Vac 2
26 Time delay relay 10 A 240 Vac 3
27 Triple pole Contactor 20A 240Vac 3
28 Batten type Lamp holder 240Vac 10 A 3
29 Start stop button 240Vac 10A 2
30 Indicating light (Bulb ) 240Vac 25W 3
31 Overload Relay 415V 20A 1
32 Three phase dahlander type
induction motor
5 hp 1
33 Single phase step down
transformer
24024Vac
2500VA
1
79 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
34 Single core PVC insulated
Cable
1mm 2 As required
35 Single core PVC insulated
Cable
25mm 2 As required
36 DIN rail 35 mm As required
37 PVC type Cable tray 50 mm x 50 mm As required
38 Cable ties 4 ldquo As required
39 Flexible wires 075 mm As required
40 PVC Connectors 5 A amp 20 A 240 V As required
41 Terminal block 20A 240Vac As required
Procedures
5 Identify each component according to specification and quantity required from the schematic
diagram attached
6 Test the functionality of each component by using multi-meter or power supply whichever
applicable
7 Wire component according to circuit diagram
8 Three motors operated in sequence by DOL starter operated by manual push button or time
delay relay
a One loop per-cycle
b Continuous operation in a loop
c optional circuit design to represent the same task
d Only one out of three motors to be operated at a time (quiz)
9 Test the functionality of completed project
80 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
BASIC DESIGN INDUSTRIAL MOTOR CONTROL (SEQUENCE CONTROL)
THREE PHASE INDUCTION MOTOR OPERATED IN SEQUENCE BY DIRECT ON LINE
STARTER
LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
81 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
82 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Lcd lamp indicator 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
11 Overload Relay 415V 20A 3
12 Three phase induction motor 5 hp 3
13 Single phase step down transformer 2500VA 1
14 Single core PVC insulated Cable 1mm 2 As required
15 Single core PVC insulated Cable 25mm 2 As required
16 DIN rail 35 mm As required
17 PVC type Cable tray 50 mm x 50 mm As required
18 Cable ties 4 ldquo As required
19 Flexible wires 1 mm Oslash As required
20 PVC Terminal block 10A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the schematic
diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a optional exercise
i Forward Reverse dahlander motor
4 Test the functionality of completed project
83 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
THREE PHASE DAHLANDER TYPE INDUCTION MOTOR OPERATED FORWARD AND
REVERSE OPERATION BY DIRECT ON LINE STARTER
84 ndash 99EASYTECH ENTERPRISE
LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
Introduction
If a motors windings are connected in the star configuration any two phases will be in series across
the supply and hence the line current will be smaller(by 577) than if the windings were connected in
the delta arrangement
Hence larger-type motors with heavy starting currents are first connected in star and then when the
starting currents fall in delta This of course means that all six of the ends of the windings must be
brought to terminations outside the casing (Fig 833)
EZTECH
EZTECH ELECTRICAL INSTALLATION GUIDE
The automatic version of this starter incorporates a timing relay which automatically changes the
connections from star to delta Figs 834 and 835 show the wiring and schematic diagrams for a star
delta starter
Objectives
1 Identify component and the specification
2 Design forward reverse star delta starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
2 ndash 99EASYTECH ENTERPRISE
REV -C
LEGENDMCCB Moulded Case Circuit BreakerTOR Thermal Over Load RelayFOW-C Mains Forward ContactorREV-C Mains Reverse ContactorDC Delta ContactorSC Star ContactorS-SW Mains Selector Switch
SC
V2
W2
U2
DC
V1
W1
U1
TOR
TOR
FOW-C
30A MCCB
TOR
MAIN CIRCUIT FORWARD REVERSE STAR DELTA
RYBN S
-SW
3 PHASEINDUCTION MOTOR
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Relay 10 A 240V 3
5 Triple pole Contactor
6 cw NO NC auxiliary contact
240Vac 20 A 4
7 Overload Relay 415 V 1
8 LED indicator 240vac 5 A 4
9 Start stop button 240Vac 5A 2
10 DIN rail 35 mm As required
11 Flexible wires 1 mm As required
12 Single core PVC insulated
wire
25 mm As required
13 Terminal block 20 A As required
14 Squirrel cage motor 5kW 1
15 5 pin plug and socket 415V 20A 1
16 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
3 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
a Manual star delta
b Manual Forward reverse star delta starter
c Automatic star delta starter
d Automatic Forward reverse star delta starter
4 Test the functionality of completed project
4 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
Objectives
1 Identify component and the specification
2 Design auto transformer starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
5 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Autotransformer starter is used to start a 3 phase induction motor that has a rating between 10 to 15 hp
6 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Autotransformer set 10Kw 415 V 50 Hz 1
5 Triple pole Contactor 240Vac 4
6 Batten type Lamp holder 240 Vac 105 A 4
7 Start stop button 240Vac 10A 4
8 Filament lamp (Bulb ) 240Vac 40W 4
9 DIN rail 35 mm As required
10 Flexible wires 1 mm As required
7 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
11 Single core PVC insulated
wire
25 mm As required
12 Terminal block 20 A As required
13 Squirrel cage motor 10kW 1
14 5 pin plug and socket 415V 20A 1
15 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a open transient autotransformer starter
b close transient autotransformer starter
c Forward reverse autotransformer starter
4 Test the functionality of completed project
8 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
Objectives
1 Identify component and the specification
2 Design rotor resistance starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
9 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Rotor Resistor set 10kW 1
5 Triple pole Contactor 240Vac 20A 4
6 Indicating light 240vac 5 A 4
7 Start stop push button 240Vac 5A 4
8 DIN rail 35 mm As required
9 Flexible wires 1 mm 2 As required
10 Single core PVC insulated wire 25 mm 2 As required
11 Terminal block 20 A As required
12 Slip Ring motor 10kW 1
13 5 pin round 3 phase socket 415V 20A 1
14 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
10 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
4 Test the functionality of completed project
a Dead circuit test b Life circuit test
5 Measure starting and running Amps
LESSON 16
TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
An installation in general will suffer damage
Damage usually occurs on the electric motor control as follows
1 Damage to the main circuit
2 Damage to the control circuit
The cause of the damage
i Overcurrent overload short circuit
ii Leakage current to ground
iii Equipment malfunction
iv The main control circuit
a Trip of main circuit protection devices fire
b Defect of motor terminal such as short circuit fire loose
v The control circuit is not functioning -
a contactor relay relay time overload relay does not work damaged burned
b Loose cable connection disconnected
Detecting and Repairing Damage
Examples of damage are as follows
i Motor does not work
ii Motor function and overload relay trips
iii Motor function but only partially functional control circuit
Methods of detecting damage
Among the known methods necessary to detect damage are as follows
1 Turn off the electricity at the main switch (main switch) in order to avoid any danger during the
work carried out to detect damage
2 Check all the protective gear that controls the motor control main circuit
11 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
3 Make sure the damage function control circuit
4 Check the control circuit according to the schematic circuit diagram of the motor control
5 Check the operation of the control circuit
Note
Use wiring that has been installed on the SYSTEM OF MOTOR CONTROL BOARD by Forward
Reverse control circuit for Star Delta to test and look for damage
SELF-ASSESSMENT QUESTIONS
1 (a) Explain what is meant by the term lsquoback emfrsquo in a motor
(b) Outline the basic differences between series shunt and compound wound dc motors
2 (a) With the aid of diagrams explain how the speed of series shunt and compound-wound motors
may be controlled
(b) A 440V dc shunt-wound motor has a field resistance of 200R and an armature resistance of 06 R
When its speed is 20 rev d second the current drawn from the supply is 122A Calculate its back
emf at this speed If the speed were decreased to 19 revssecond the field flux remaining unchanged
calculate the new back emf and the new armature current
3 A load of 64 kW at 240 V is supplied from the terminals of a shunt-wound dc generator The field
resistance is 180 A Calculate the armature current
4 (a) Explain with the aid of a diagram how a rotating magnetic field may be
(b) What is meant by lsquosynchronous speedrsquo
Calculate the synchronous obtained speed of a 12 pole motor if the supply frequency is 50Hz
5 (a) Explain the action of a synchronous motor
(b) What methods are available to start a synchronous motor Explain with diagrams
6 (a) Explain the action of a cage induction motor
(b) What is meant by the term lsquosliprsquo
Calculate the percentage slip of a six pole induction motor running at 162 revssecond from a 50 Hz
supply
7 Describe with sketches three different ways of starting a single-phase induction motor
12 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
8 Explain with the aid of a sketch the action of a three-phase DOL starter
What are dashpots used for How are remote start and stop buttons connected
9 A I0 kW 240V 50Hz single-phase cage rotor induction motor is 85efficient and has a PF of 068
lagging Calculate the motor current and the value of capacitor required to raise the PF to 093
lagging
10 Calculate the torque developed by an 18 kW four-pole induction motor run at 35 slip from a
50Hz supply
APPENDIX 1
13 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 11
14 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 111
Attachment Reference
httpswwwtlc-directcoukBook621htm
httpwwwstgovmyindexphpms
15 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
i Ensure that the residual current device (RCD) trips within the set time on the occurrence of current
leakage to earth
ii Test Equipment ndash RCD Tester RCCB Tester
iii Test Method 1
1 1048766 Use the Trip Test Button
2 1048766 Press the trip button found on the RCD to determine if it trips or otherwise This test would
not be able to determine the sensitivity of the RCD nor the time taken for it to trip
iv Test Method 2
1048766 Use a RCD Tester
This equipment is equipped with a 13A plug which can be connected to a 13A socket outlet Select the
RCD sensitivity to be the same as the sensitivity of the RCD to be tested to determine if the RCD can
trip The time to trip shall not exceed 40 mS
1048766 Test method ndash
a) Position the selection switch in accordance with the sensitivity of the RCD used
Example 100 mA 01 A
b) Position the operations switch to lsquoNo Triprsquo (frac12 Rated mA = 50) connect the 3 pin plug to
the 13A socket outlet
c) Switch on the 13A socket outlet ndash ensure that the P-N and P-E lights light up This shows that
the polarity is correct (Note if both the lights as above do not light up the test cannot be
continued)
d) Press the test button ndash the reading shows less than 200 millisecond and simultaneously the
lsquotestrsquo light lights up and the P-N and P-E lights do not light up At that instant the RCD will
not trip
e) Move the selection switch to 180o (+ve wave) ndash repeat steps (d) and (e) = 100)
f) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
g) Move the selection switch to 0o (-ve wave)
h) Press the test button ndash RCD will trip and the indicated reading shall not exceed 200 mS
i) The above test is repeated until a near correct reading is obtained
j) Record the test results
k) Change the operations switch to lsquoFast Triprsquo and press the test button ndash RCD will trip within a
time not exceeding 40 mS
l) Repeat a number of times at 0o or 180o
72 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 9 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (DC)
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
73 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Start stop button 240Vac 5A 2
9 Filament lamp (Bulb ) 240Vac 40W 3
10 Overload Relay 415V 20A 3
11 Three phase induction motor 5 hp 3
12 Single phase step down transformer 2500VA 1
13 Single core PVC insulated Cable 1mm 2 As required
14 Single core PVC insulated Cable 25mm 2 As required
15 DIN rail 35 mm As required
16 PVC type Cable tray 50 mm x 50 mm As required
17 Cable ties 4 ldquo As required
18 Flexible wires 05 mm As required
19 PVC Connectors 5 A amp 20 A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the schematic
diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a optional exercise
i Simple DOL starter
ii Forward reverse DOL starter
iii Forward Reverse Dahlander motor
iv Three motors operated in sequence by DOL starter operated by manual push
button or time delay relay
74 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
a One loop per-cycle
b Continuous operation in a loop
c optional circuit design to represent the same task
v Only one out of three motors to be operated at a time (quiz)
4 Test the functionality of completed project
LESSON 10 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (AC)
75 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 1
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Lamp point 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
76 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
11 Overload Relay 415V 20A 3
12 Three phase induction
motor
5 hp 3
13 Single core PVC insulated
Cable
1mm 2 As required
14 Single core PVC insulated
Cable
25mm 2 As required
15 DIN rail 35 mm As required
16 PVC type Cable tray 50 mm x 50 mm As required
17 Cable ties 4 ldquo As required
18 Flexible wires 05 mm As required
19 PVC Connectors 5 A amp 20 A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the
schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram optional exercise
4 Simple DOL starter
5 Forward reverse DOL starter
6 Test the functionality of completed project
77 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 1
78 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
cm
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Indicating light 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
11 Overload Relay 415V 20A 3
12 Three phase induction motor 5 hp 3
13 Single phase step down
transformer
2500VA 1
14 Single core PVC insulated
Cable
1mm 2 As required
15 Single core PVC insulated
Cable
25mm 2 As required
16 DIN rail 35 mm As required
17 PVC type Cable tray 50 mm x 50 mm As required
18 Cable ties 4 ldquo As required
19 Flexible wires 05 mm As required
20 PVC Connectors 5 A amp 20 A 240 V As required
21 Single pole MCB 6A 240 V 1
22 Single pole MCB 2A 240 V 1
23 Triple pole MCB 20A 415 V 1
24 Mounting board 30 cm x 40 cm x 3
cm
1
25 Relay cw 11 pin socket 10 A 240 Vac 2
26 Time delay relay 10 A 240 Vac 3
27 Triple pole Contactor 20A 240Vac 3
28 Batten type Lamp holder 240Vac 10 A 3
29 Start stop button 240Vac 10A 2
30 Indicating light (Bulb ) 240Vac 25W 3
31 Overload Relay 415V 20A 1
32 Three phase dahlander type
induction motor
5 hp 1
33 Single phase step down
transformer
24024Vac
2500VA
1
79 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
34 Single core PVC insulated
Cable
1mm 2 As required
35 Single core PVC insulated
Cable
25mm 2 As required
36 DIN rail 35 mm As required
37 PVC type Cable tray 50 mm x 50 mm As required
38 Cable ties 4 ldquo As required
39 Flexible wires 075 mm As required
40 PVC Connectors 5 A amp 20 A 240 V As required
41 Terminal block 20A 240Vac As required
Procedures
5 Identify each component according to specification and quantity required from the schematic
diagram attached
6 Test the functionality of each component by using multi-meter or power supply whichever
applicable
7 Wire component according to circuit diagram
8 Three motors operated in sequence by DOL starter operated by manual push button or time
delay relay
a One loop per-cycle
b Continuous operation in a loop
c optional circuit design to represent the same task
d Only one out of three motors to be operated at a time (quiz)
9 Test the functionality of completed project
80 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
BASIC DESIGN INDUSTRIAL MOTOR CONTROL (SEQUENCE CONTROL)
THREE PHASE INDUCTION MOTOR OPERATED IN SEQUENCE BY DIRECT ON LINE
STARTER
LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
81 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
82 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Lcd lamp indicator 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
11 Overload Relay 415V 20A 3
12 Three phase induction motor 5 hp 3
13 Single phase step down transformer 2500VA 1
14 Single core PVC insulated Cable 1mm 2 As required
15 Single core PVC insulated Cable 25mm 2 As required
16 DIN rail 35 mm As required
17 PVC type Cable tray 50 mm x 50 mm As required
18 Cable ties 4 ldquo As required
19 Flexible wires 1 mm Oslash As required
20 PVC Terminal block 10A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the schematic
diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a optional exercise
i Forward Reverse dahlander motor
4 Test the functionality of completed project
83 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
THREE PHASE DAHLANDER TYPE INDUCTION MOTOR OPERATED FORWARD AND
REVERSE OPERATION BY DIRECT ON LINE STARTER
84 ndash 99EASYTECH ENTERPRISE
LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
Introduction
If a motors windings are connected in the star configuration any two phases will be in series across
the supply and hence the line current will be smaller(by 577) than if the windings were connected in
the delta arrangement
Hence larger-type motors with heavy starting currents are first connected in star and then when the
starting currents fall in delta This of course means that all six of the ends of the windings must be
brought to terminations outside the casing (Fig 833)
EZTECH
EZTECH ELECTRICAL INSTALLATION GUIDE
The automatic version of this starter incorporates a timing relay which automatically changes the
connections from star to delta Figs 834 and 835 show the wiring and schematic diagrams for a star
delta starter
Objectives
1 Identify component and the specification
2 Design forward reverse star delta starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
2 ndash 99EASYTECH ENTERPRISE
REV -C
LEGENDMCCB Moulded Case Circuit BreakerTOR Thermal Over Load RelayFOW-C Mains Forward ContactorREV-C Mains Reverse ContactorDC Delta ContactorSC Star ContactorS-SW Mains Selector Switch
SC
V2
W2
U2
DC
V1
W1
U1
TOR
TOR
FOW-C
30A MCCB
TOR
MAIN CIRCUIT FORWARD REVERSE STAR DELTA
RYBN S
-SW
3 PHASEINDUCTION MOTOR
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Relay 10 A 240V 3
5 Triple pole Contactor
6 cw NO NC auxiliary contact
240Vac 20 A 4
7 Overload Relay 415 V 1
8 LED indicator 240vac 5 A 4
9 Start stop button 240Vac 5A 2
10 DIN rail 35 mm As required
11 Flexible wires 1 mm As required
12 Single core PVC insulated
wire
25 mm As required
13 Terminal block 20 A As required
14 Squirrel cage motor 5kW 1
15 5 pin plug and socket 415V 20A 1
16 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
3 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
a Manual star delta
b Manual Forward reverse star delta starter
c Automatic star delta starter
d Automatic Forward reverse star delta starter
4 Test the functionality of completed project
4 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
Objectives
1 Identify component and the specification
2 Design auto transformer starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
5 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Autotransformer starter is used to start a 3 phase induction motor that has a rating between 10 to 15 hp
6 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Autotransformer set 10Kw 415 V 50 Hz 1
5 Triple pole Contactor 240Vac 4
6 Batten type Lamp holder 240 Vac 105 A 4
7 Start stop button 240Vac 10A 4
8 Filament lamp (Bulb ) 240Vac 40W 4
9 DIN rail 35 mm As required
10 Flexible wires 1 mm As required
7 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
11 Single core PVC insulated
wire
25 mm As required
12 Terminal block 20 A As required
13 Squirrel cage motor 10kW 1
14 5 pin plug and socket 415V 20A 1
15 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a open transient autotransformer starter
b close transient autotransformer starter
c Forward reverse autotransformer starter
4 Test the functionality of completed project
8 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
Objectives
1 Identify component and the specification
2 Design rotor resistance starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
9 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Rotor Resistor set 10kW 1
5 Triple pole Contactor 240Vac 20A 4
6 Indicating light 240vac 5 A 4
7 Start stop push button 240Vac 5A 4
8 DIN rail 35 mm As required
9 Flexible wires 1 mm 2 As required
10 Single core PVC insulated wire 25 mm 2 As required
11 Terminal block 20 A As required
12 Slip Ring motor 10kW 1
13 5 pin round 3 phase socket 415V 20A 1
14 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
10 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
4 Test the functionality of completed project
a Dead circuit test b Life circuit test
5 Measure starting and running Amps
LESSON 16
TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
An installation in general will suffer damage
Damage usually occurs on the electric motor control as follows
1 Damage to the main circuit
2 Damage to the control circuit
The cause of the damage
i Overcurrent overload short circuit
ii Leakage current to ground
iii Equipment malfunction
iv The main control circuit
a Trip of main circuit protection devices fire
b Defect of motor terminal such as short circuit fire loose
v The control circuit is not functioning -
a contactor relay relay time overload relay does not work damaged burned
b Loose cable connection disconnected
Detecting and Repairing Damage
Examples of damage are as follows
i Motor does not work
ii Motor function and overload relay trips
iii Motor function but only partially functional control circuit
Methods of detecting damage
Among the known methods necessary to detect damage are as follows
1 Turn off the electricity at the main switch (main switch) in order to avoid any danger during the
work carried out to detect damage
2 Check all the protective gear that controls the motor control main circuit
11 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
3 Make sure the damage function control circuit
4 Check the control circuit according to the schematic circuit diagram of the motor control
5 Check the operation of the control circuit
Note
Use wiring that has been installed on the SYSTEM OF MOTOR CONTROL BOARD by Forward
Reverse control circuit for Star Delta to test and look for damage
SELF-ASSESSMENT QUESTIONS
1 (a) Explain what is meant by the term lsquoback emfrsquo in a motor
(b) Outline the basic differences between series shunt and compound wound dc motors
2 (a) With the aid of diagrams explain how the speed of series shunt and compound-wound motors
may be controlled
(b) A 440V dc shunt-wound motor has a field resistance of 200R and an armature resistance of 06 R
When its speed is 20 rev d second the current drawn from the supply is 122A Calculate its back
emf at this speed If the speed were decreased to 19 revssecond the field flux remaining unchanged
calculate the new back emf and the new armature current
3 A load of 64 kW at 240 V is supplied from the terminals of a shunt-wound dc generator The field
resistance is 180 A Calculate the armature current
4 (a) Explain with the aid of a diagram how a rotating magnetic field may be
(b) What is meant by lsquosynchronous speedrsquo
Calculate the synchronous obtained speed of a 12 pole motor if the supply frequency is 50Hz
5 (a) Explain the action of a synchronous motor
(b) What methods are available to start a synchronous motor Explain with diagrams
6 (a) Explain the action of a cage induction motor
(b) What is meant by the term lsquosliprsquo
Calculate the percentage slip of a six pole induction motor running at 162 revssecond from a 50 Hz
supply
7 Describe with sketches three different ways of starting a single-phase induction motor
12 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
8 Explain with the aid of a sketch the action of a three-phase DOL starter
What are dashpots used for How are remote start and stop buttons connected
9 A I0 kW 240V 50Hz single-phase cage rotor induction motor is 85efficient and has a PF of 068
lagging Calculate the motor current and the value of capacitor required to raise the PF to 093
lagging
10 Calculate the torque developed by an 18 kW four-pole induction motor run at 35 slip from a
50Hz supply
APPENDIX 1
13 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 11
14 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 111
Attachment Reference
httpswwwtlc-directcoukBook621htm
httpwwwstgovmyindexphpms
15 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 9 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (DC)
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
73 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Start stop button 240Vac 5A 2
9 Filament lamp (Bulb ) 240Vac 40W 3
10 Overload Relay 415V 20A 3
11 Three phase induction motor 5 hp 3
12 Single phase step down transformer 2500VA 1
13 Single core PVC insulated Cable 1mm 2 As required
14 Single core PVC insulated Cable 25mm 2 As required
15 DIN rail 35 mm As required
16 PVC type Cable tray 50 mm x 50 mm As required
17 Cable ties 4 ldquo As required
18 Flexible wires 05 mm As required
19 PVC Connectors 5 A amp 20 A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the schematic
diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a optional exercise
i Simple DOL starter
ii Forward reverse DOL starter
iii Forward Reverse Dahlander motor
iv Three motors operated in sequence by DOL starter operated by manual push
button or time delay relay
74 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
a One loop per-cycle
b Continuous operation in a loop
c optional circuit design to represent the same task
v Only one out of three motors to be operated at a time (quiz)
4 Test the functionality of completed project
LESSON 10 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (AC)
75 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 1
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Lamp point 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
76 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
11 Overload Relay 415V 20A 3
12 Three phase induction
motor
5 hp 3
13 Single core PVC insulated
Cable
1mm 2 As required
14 Single core PVC insulated
Cable
25mm 2 As required
15 DIN rail 35 mm As required
16 PVC type Cable tray 50 mm x 50 mm As required
17 Cable ties 4 ldquo As required
18 Flexible wires 05 mm As required
19 PVC Connectors 5 A amp 20 A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the
schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram optional exercise
4 Simple DOL starter
5 Forward reverse DOL starter
6 Test the functionality of completed project
77 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 1
78 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
cm
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Indicating light 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
11 Overload Relay 415V 20A 3
12 Three phase induction motor 5 hp 3
13 Single phase step down
transformer
2500VA 1
14 Single core PVC insulated
Cable
1mm 2 As required
15 Single core PVC insulated
Cable
25mm 2 As required
16 DIN rail 35 mm As required
17 PVC type Cable tray 50 mm x 50 mm As required
18 Cable ties 4 ldquo As required
19 Flexible wires 05 mm As required
20 PVC Connectors 5 A amp 20 A 240 V As required
21 Single pole MCB 6A 240 V 1
22 Single pole MCB 2A 240 V 1
23 Triple pole MCB 20A 415 V 1
24 Mounting board 30 cm x 40 cm x 3
cm
1
25 Relay cw 11 pin socket 10 A 240 Vac 2
26 Time delay relay 10 A 240 Vac 3
27 Triple pole Contactor 20A 240Vac 3
28 Batten type Lamp holder 240Vac 10 A 3
29 Start stop button 240Vac 10A 2
30 Indicating light (Bulb ) 240Vac 25W 3
31 Overload Relay 415V 20A 1
32 Three phase dahlander type
induction motor
5 hp 1
33 Single phase step down
transformer
24024Vac
2500VA
1
79 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
34 Single core PVC insulated
Cable
1mm 2 As required
35 Single core PVC insulated
Cable
25mm 2 As required
36 DIN rail 35 mm As required
37 PVC type Cable tray 50 mm x 50 mm As required
38 Cable ties 4 ldquo As required
39 Flexible wires 075 mm As required
40 PVC Connectors 5 A amp 20 A 240 V As required
41 Terminal block 20A 240Vac As required
Procedures
5 Identify each component according to specification and quantity required from the schematic
diagram attached
6 Test the functionality of each component by using multi-meter or power supply whichever
applicable
7 Wire component according to circuit diagram
8 Three motors operated in sequence by DOL starter operated by manual push button or time
delay relay
a One loop per-cycle
b Continuous operation in a loop
c optional circuit design to represent the same task
d Only one out of three motors to be operated at a time (quiz)
9 Test the functionality of completed project
80 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
BASIC DESIGN INDUSTRIAL MOTOR CONTROL (SEQUENCE CONTROL)
THREE PHASE INDUCTION MOTOR OPERATED IN SEQUENCE BY DIRECT ON LINE
STARTER
LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
81 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
82 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Lcd lamp indicator 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
11 Overload Relay 415V 20A 3
12 Three phase induction motor 5 hp 3
13 Single phase step down transformer 2500VA 1
14 Single core PVC insulated Cable 1mm 2 As required
15 Single core PVC insulated Cable 25mm 2 As required
16 DIN rail 35 mm As required
17 PVC type Cable tray 50 mm x 50 mm As required
18 Cable ties 4 ldquo As required
19 Flexible wires 1 mm Oslash As required
20 PVC Terminal block 10A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the schematic
diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a optional exercise
i Forward Reverse dahlander motor
4 Test the functionality of completed project
83 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
THREE PHASE DAHLANDER TYPE INDUCTION MOTOR OPERATED FORWARD AND
REVERSE OPERATION BY DIRECT ON LINE STARTER
84 ndash 99EASYTECH ENTERPRISE
LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
Introduction
If a motors windings are connected in the star configuration any two phases will be in series across
the supply and hence the line current will be smaller(by 577) than if the windings were connected in
the delta arrangement
Hence larger-type motors with heavy starting currents are first connected in star and then when the
starting currents fall in delta This of course means that all six of the ends of the windings must be
brought to terminations outside the casing (Fig 833)
EZTECH
EZTECH ELECTRICAL INSTALLATION GUIDE
The automatic version of this starter incorporates a timing relay which automatically changes the
connections from star to delta Figs 834 and 835 show the wiring and schematic diagrams for a star
delta starter
Objectives
1 Identify component and the specification
2 Design forward reverse star delta starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
2 ndash 99EASYTECH ENTERPRISE
REV -C
LEGENDMCCB Moulded Case Circuit BreakerTOR Thermal Over Load RelayFOW-C Mains Forward ContactorREV-C Mains Reverse ContactorDC Delta ContactorSC Star ContactorS-SW Mains Selector Switch
SC
V2
W2
U2
DC
V1
W1
U1
TOR
TOR
FOW-C
30A MCCB
TOR
MAIN CIRCUIT FORWARD REVERSE STAR DELTA
RYBN S
-SW
3 PHASEINDUCTION MOTOR
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Relay 10 A 240V 3
5 Triple pole Contactor
6 cw NO NC auxiliary contact
240Vac 20 A 4
7 Overload Relay 415 V 1
8 LED indicator 240vac 5 A 4
9 Start stop button 240Vac 5A 2
10 DIN rail 35 mm As required
11 Flexible wires 1 mm As required
12 Single core PVC insulated
wire
25 mm As required
13 Terminal block 20 A As required
14 Squirrel cage motor 5kW 1
15 5 pin plug and socket 415V 20A 1
16 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
3 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
a Manual star delta
b Manual Forward reverse star delta starter
c Automatic star delta starter
d Automatic Forward reverse star delta starter
4 Test the functionality of completed project
4 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
Objectives
1 Identify component and the specification
2 Design auto transformer starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
5 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Autotransformer starter is used to start a 3 phase induction motor that has a rating between 10 to 15 hp
6 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Autotransformer set 10Kw 415 V 50 Hz 1
5 Triple pole Contactor 240Vac 4
6 Batten type Lamp holder 240 Vac 105 A 4
7 Start stop button 240Vac 10A 4
8 Filament lamp (Bulb ) 240Vac 40W 4
9 DIN rail 35 mm As required
10 Flexible wires 1 mm As required
7 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
11 Single core PVC insulated
wire
25 mm As required
12 Terminal block 20 A As required
13 Squirrel cage motor 10kW 1
14 5 pin plug and socket 415V 20A 1
15 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a open transient autotransformer starter
b close transient autotransformer starter
c Forward reverse autotransformer starter
4 Test the functionality of completed project
8 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
Objectives
1 Identify component and the specification
2 Design rotor resistance starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
9 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Rotor Resistor set 10kW 1
5 Triple pole Contactor 240Vac 20A 4
6 Indicating light 240vac 5 A 4
7 Start stop push button 240Vac 5A 4
8 DIN rail 35 mm As required
9 Flexible wires 1 mm 2 As required
10 Single core PVC insulated wire 25 mm 2 As required
11 Terminal block 20 A As required
12 Slip Ring motor 10kW 1
13 5 pin round 3 phase socket 415V 20A 1
14 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
10 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
4 Test the functionality of completed project
a Dead circuit test b Life circuit test
5 Measure starting and running Amps
LESSON 16
TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
An installation in general will suffer damage
Damage usually occurs on the electric motor control as follows
1 Damage to the main circuit
2 Damage to the control circuit
The cause of the damage
i Overcurrent overload short circuit
ii Leakage current to ground
iii Equipment malfunction
iv The main control circuit
a Trip of main circuit protection devices fire
b Defect of motor terminal such as short circuit fire loose
v The control circuit is not functioning -
a contactor relay relay time overload relay does not work damaged burned
b Loose cable connection disconnected
Detecting and Repairing Damage
Examples of damage are as follows
i Motor does not work
ii Motor function and overload relay trips
iii Motor function but only partially functional control circuit
Methods of detecting damage
Among the known methods necessary to detect damage are as follows
1 Turn off the electricity at the main switch (main switch) in order to avoid any danger during the
work carried out to detect damage
2 Check all the protective gear that controls the motor control main circuit
11 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
3 Make sure the damage function control circuit
4 Check the control circuit according to the schematic circuit diagram of the motor control
5 Check the operation of the control circuit
Note
Use wiring that has been installed on the SYSTEM OF MOTOR CONTROL BOARD by Forward
Reverse control circuit for Star Delta to test and look for damage
SELF-ASSESSMENT QUESTIONS
1 (a) Explain what is meant by the term lsquoback emfrsquo in a motor
(b) Outline the basic differences between series shunt and compound wound dc motors
2 (a) With the aid of diagrams explain how the speed of series shunt and compound-wound motors
may be controlled
(b) A 440V dc shunt-wound motor has a field resistance of 200R and an armature resistance of 06 R
When its speed is 20 rev d second the current drawn from the supply is 122A Calculate its back
emf at this speed If the speed were decreased to 19 revssecond the field flux remaining unchanged
calculate the new back emf and the new armature current
3 A load of 64 kW at 240 V is supplied from the terminals of a shunt-wound dc generator The field
resistance is 180 A Calculate the armature current
4 (a) Explain with the aid of a diagram how a rotating magnetic field may be
(b) What is meant by lsquosynchronous speedrsquo
Calculate the synchronous obtained speed of a 12 pole motor if the supply frequency is 50Hz
5 (a) Explain the action of a synchronous motor
(b) What methods are available to start a synchronous motor Explain with diagrams
6 (a) Explain the action of a cage induction motor
(b) What is meant by the term lsquosliprsquo
Calculate the percentage slip of a six pole induction motor running at 162 revssecond from a 50 Hz
supply
7 Describe with sketches three different ways of starting a single-phase induction motor
12 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
8 Explain with the aid of a sketch the action of a three-phase DOL starter
What are dashpots used for How are remote start and stop buttons connected
9 A I0 kW 240V 50Hz single-phase cage rotor induction motor is 85efficient and has a PF of 068
lagging Calculate the motor current and the value of capacitor required to raise the PF to 093
lagging
10 Calculate the torque developed by an 18 kW four-pole induction motor run at 35 slip from a
50Hz supply
APPENDIX 1
13 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 11
14 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 111
Attachment Reference
httpswwwtlc-directcoukBook621htm
httpwwwstgovmyindexphpms
15 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Start stop button 240Vac 5A 2
9 Filament lamp (Bulb ) 240Vac 40W 3
10 Overload Relay 415V 20A 3
11 Three phase induction motor 5 hp 3
12 Single phase step down transformer 2500VA 1
13 Single core PVC insulated Cable 1mm 2 As required
14 Single core PVC insulated Cable 25mm 2 As required
15 DIN rail 35 mm As required
16 PVC type Cable tray 50 mm x 50 mm As required
17 Cable ties 4 ldquo As required
18 Flexible wires 05 mm As required
19 PVC Connectors 5 A amp 20 A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the schematic
diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a optional exercise
i Simple DOL starter
ii Forward reverse DOL starter
iii Forward Reverse Dahlander motor
iv Three motors operated in sequence by DOL starter operated by manual push
button or time delay relay
74 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
a One loop per-cycle
b Continuous operation in a loop
c optional circuit design to represent the same task
v Only one out of three motors to be operated at a time (quiz)
4 Test the functionality of completed project
LESSON 10 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (AC)
75 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 1
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Lamp point 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
76 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
11 Overload Relay 415V 20A 3
12 Three phase induction
motor
5 hp 3
13 Single core PVC insulated
Cable
1mm 2 As required
14 Single core PVC insulated
Cable
25mm 2 As required
15 DIN rail 35 mm As required
16 PVC type Cable tray 50 mm x 50 mm As required
17 Cable ties 4 ldquo As required
18 Flexible wires 05 mm As required
19 PVC Connectors 5 A amp 20 A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the
schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram optional exercise
4 Simple DOL starter
5 Forward reverse DOL starter
6 Test the functionality of completed project
77 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 1
78 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
cm
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Indicating light 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
11 Overload Relay 415V 20A 3
12 Three phase induction motor 5 hp 3
13 Single phase step down
transformer
2500VA 1
14 Single core PVC insulated
Cable
1mm 2 As required
15 Single core PVC insulated
Cable
25mm 2 As required
16 DIN rail 35 mm As required
17 PVC type Cable tray 50 mm x 50 mm As required
18 Cable ties 4 ldquo As required
19 Flexible wires 05 mm As required
20 PVC Connectors 5 A amp 20 A 240 V As required
21 Single pole MCB 6A 240 V 1
22 Single pole MCB 2A 240 V 1
23 Triple pole MCB 20A 415 V 1
24 Mounting board 30 cm x 40 cm x 3
cm
1
25 Relay cw 11 pin socket 10 A 240 Vac 2
26 Time delay relay 10 A 240 Vac 3
27 Triple pole Contactor 20A 240Vac 3
28 Batten type Lamp holder 240Vac 10 A 3
29 Start stop button 240Vac 10A 2
30 Indicating light (Bulb ) 240Vac 25W 3
31 Overload Relay 415V 20A 1
32 Three phase dahlander type
induction motor
5 hp 1
33 Single phase step down
transformer
24024Vac
2500VA
1
79 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
34 Single core PVC insulated
Cable
1mm 2 As required
35 Single core PVC insulated
Cable
25mm 2 As required
36 DIN rail 35 mm As required
37 PVC type Cable tray 50 mm x 50 mm As required
38 Cable ties 4 ldquo As required
39 Flexible wires 075 mm As required
40 PVC Connectors 5 A amp 20 A 240 V As required
41 Terminal block 20A 240Vac As required
Procedures
5 Identify each component according to specification and quantity required from the schematic
diagram attached
6 Test the functionality of each component by using multi-meter or power supply whichever
applicable
7 Wire component according to circuit diagram
8 Three motors operated in sequence by DOL starter operated by manual push button or time
delay relay
a One loop per-cycle
b Continuous operation in a loop
c optional circuit design to represent the same task
d Only one out of three motors to be operated at a time (quiz)
9 Test the functionality of completed project
80 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
BASIC DESIGN INDUSTRIAL MOTOR CONTROL (SEQUENCE CONTROL)
THREE PHASE INDUCTION MOTOR OPERATED IN SEQUENCE BY DIRECT ON LINE
STARTER
LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
81 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
82 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Lcd lamp indicator 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
11 Overload Relay 415V 20A 3
12 Three phase induction motor 5 hp 3
13 Single phase step down transformer 2500VA 1
14 Single core PVC insulated Cable 1mm 2 As required
15 Single core PVC insulated Cable 25mm 2 As required
16 DIN rail 35 mm As required
17 PVC type Cable tray 50 mm x 50 mm As required
18 Cable ties 4 ldquo As required
19 Flexible wires 1 mm Oslash As required
20 PVC Terminal block 10A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the schematic
diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a optional exercise
i Forward Reverse dahlander motor
4 Test the functionality of completed project
83 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
THREE PHASE DAHLANDER TYPE INDUCTION MOTOR OPERATED FORWARD AND
REVERSE OPERATION BY DIRECT ON LINE STARTER
84 ndash 99EASYTECH ENTERPRISE
LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
Introduction
If a motors windings are connected in the star configuration any two phases will be in series across
the supply and hence the line current will be smaller(by 577) than if the windings were connected in
the delta arrangement
Hence larger-type motors with heavy starting currents are first connected in star and then when the
starting currents fall in delta This of course means that all six of the ends of the windings must be
brought to terminations outside the casing (Fig 833)
EZTECH
EZTECH ELECTRICAL INSTALLATION GUIDE
The automatic version of this starter incorporates a timing relay which automatically changes the
connections from star to delta Figs 834 and 835 show the wiring and schematic diagrams for a star
delta starter
Objectives
1 Identify component and the specification
2 Design forward reverse star delta starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
2 ndash 99EASYTECH ENTERPRISE
REV -C
LEGENDMCCB Moulded Case Circuit BreakerTOR Thermal Over Load RelayFOW-C Mains Forward ContactorREV-C Mains Reverse ContactorDC Delta ContactorSC Star ContactorS-SW Mains Selector Switch
SC
V2
W2
U2
DC
V1
W1
U1
TOR
TOR
FOW-C
30A MCCB
TOR
MAIN CIRCUIT FORWARD REVERSE STAR DELTA
RYBN S
-SW
3 PHASEINDUCTION MOTOR
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Relay 10 A 240V 3
5 Triple pole Contactor
6 cw NO NC auxiliary contact
240Vac 20 A 4
7 Overload Relay 415 V 1
8 LED indicator 240vac 5 A 4
9 Start stop button 240Vac 5A 2
10 DIN rail 35 mm As required
11 Flexible wires 1 mm As required
12 Single core PVC insulated
wire
25 mm As required
13 Terminal block 20 A As required
14 Squirrel cage motor 5kW 1
15 5 pin plug and socket 415V 20A 1
16 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
3 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
a Manual star delta
b Manual Forward reverse star delta starter
c Automatic star delta starter
d Automatic Forward reverse star delta starter
4 Test the functionality of completed project
4 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
Objectives
1 Identify component and the specification
2 Design auto transformer starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
5 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Autotransformer starter is used to start a 3 phase induction motor that has a rating between 10 to 15 hp
6 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Autotransformer set 10Kw 415 V 50 Hz 1
5 Triple pole Contactor 240Vac 4
6 Batten type Lamp holder 240 Vac 105 A 4
7 Start stop button 240Vac 10A 4
8 Filament lamp (Bulb ) 240Vac 40W 4
9 DIN rail 35 mm As required
10 Flexible wires 1 mm As required
7 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
11 Single core PVC insulated
wire
25 mm As required
12 Terminal block 20 A As required
13 Squirrel cage motor 10kW 1
14 5 pin plug and socket 415V 20A 1
15 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a open transient autotransformer starter
b close transient autotransformer starter
c Forward reverse autotransformer starter
4 Test the functionality of completed project
8 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
Objectives
1 Identify component and the specification
2 Design rotor resistance starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
9 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Rotor Resistor set 10kW 1
5 Triple pole Contactor 240Vac 20A 4
6 Indicating light 240vac 5 A 4
7 Start stop push button 240Vac 5A 4
8 DIN rail 35 mm As required
9 Flexible wires 1 mm 2 As required
10 Single core PVC insulated wire 25 mm 2 As required
11 Terminal block 20 A As required
12 Slip Ring motor 10kW 1
13 5 pin round 3 phase socket 415V 20A 1
14 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
10 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
4 Test the functionality of completed project
a Dead circuit test b Life circuit test
5 Measure starting and running Amps
LESSON 16
TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
An installation in general will suffer damage
Damage usually occurs on the electric motor control as follows
1 Damage to the main circuit
2 Damage to the control circuit
The cause of the damage
i Overcurrent overload short circuit
ii Leakage current to ground
iii Equipment malfunction
iv The main control circuit
a Trip of main circuit protection devices fire
b Defect of motor terminal such as short circuit fire loose
v The control circuit is not functioning -
a contactor relay relay time overload relay does not work damaged burned
b Loose cable connection disconnected
Detecting and Repairing Damage
Examples of damage are as follows
i Motor does not work
ii Motor function and overload relay trips
iii Motor function but only partially functional control circuit
Methods of detecting damage
Among the known methods necessary to detect damage are as follows
1 Turn off the electricity at the main switch (main switch) in order to avoid any danger during the
work carried out to detect damage
2 Check all the protective gear that controls the motor control main circuit
11 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
3 Make sure the damage function control circuit
4 Check the control circuit according to the schematic circuit diagram of the motor control
5 Check the operation of the control circuit
Note
Use wiring that has been installed on the SYSTEM OF MOTOR CONTROL BOARD by Forward
Reverse control circuit for Star Delta to test and look for damage
SELF-ASSESSMENT QUESTIONS
1 (a) Explain what is meant by the term lsquoback emfrsquo in a motor
(b) Outline the basic differences between series shunt and compound wound dc motors
2 (a) With the aid of diagrams explain how the speed of series shunt and compound-wound motors
may be controlled
(b) A 440V dc shunt-wound motor has a field resistance of 200R and an armature resistance of 06 R
When its speed is 20 rev d second the current drawn from the supply is 122A Calculate its back
emf at this speed If the speed were decreased to 19 revssecond the field flux remaining unchanged
calculate the new back emf and the new armature current
3 A load of 64 kW at 240 V is supplied from the terminals of a shunt-wound dc generator The field
resistance is 180 A Calculate the armature current
4 (a) Explain with the aid of a diagram how a rotating magnetic field may be
(b) What is meant by lsquosynchronous speedrsquo
Calculate the synchronous obtained speed of a 12 pole motor if the supply frequency is 50Hz
5 (a) Explain the action of a synchronous motor
(b) What methods are available to start a synchronous motor Explain with diagrams
6 (a) Explain the action of a cage induction motor
(b) What is meant by the term lsquosliprsquo
Calculate the percentage slip of a six pole induction motor running at 162 revssecond from a 50 Hz
supply
7 Describe with sketches three different ways of starting a single-phase induction motor
12 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
8 Explain with the aid of a sketch the action of a three-phase DOL starter
What are dashpots used for How are remote start and stop buttons connected
9 A I0 kW 240V 50Hz single-phase cage rotor induction motor is 85efficient and has a PF of 068
lagging Calculate the motor current and the value of capacitor required to raise the PF to 093
lagging
10 Calculate the torque developed by an 18 kW four-pole induction motor run at 35 slip from a
50Hz supply
APPENDIX 1
13 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 11
14 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 111
Attachment Reference
httpswwwtlc-directcoukBook621htm
httpwwwstgovmyindexphpms
15 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
a One loop per-cycle
b Continuous operation in a loop
c optional circuit design to represent the same task
v Only one out of three motors to be operated at a time (quiz)
4 Test the functionality of completed project
LESSON 10 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (AC)
75 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 1
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Lamp point 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
76 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
11 Overload Relay 415V 20A 3
12 Three phase induction
motor
5 hp 3
13 Single core PVC insulated
Cable
1mm 2 As required
14 Single core PVC insulated
Cable
25mm 2 As required
15 DIN rail 35 mm As required
16 PVC type Cable tray 50 mm x 50 mm As required
17 Cable ties 4 ldquo As required
18 Flexible wires 05 mm As required
19 PVC Connectors 5 A amp 20 A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the
schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram optional exercise
4 Simple DOL starter
5 Forward reverse DOL starter
6 Test the functionality of completed project
77 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 1
78 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
cm
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Indicating light 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
11 Overload Relay 415V 20A 3
12 Three phase induction motor 5 hp 3
13 Single phase step down
transformer
2500VA 1
14 Single core PVC insulated
Cable
1mm 2 As required
15 Single core PVC insulated
Cable
25mm 2 As required
16 DIN rail 35 mm As required
17 PVC type Cable tray 50 mm x 50 mm As required
18 Cable ties 4 ldquo As required
19 Flexible wires 05 mm As required
20 PVC Connectors 5 A amp 20 A 240 V As required
21 Single pole MCB 6A 240 V 1
22 Single pole MCB 2A 240 V 1
23 Triple pole MCB 20A 415 V 1
24 Mounting board 30 cm x 40 cm x 3
cm
1
25 Relay cw 11 pin socket 10 A 240 Vac 2
26 Time delay relay 10 A 240 Vac 3
27 Triple pole Contactor 20A 240Vac 3
28 Batten type Lamp holder 240Vac 10 A 3
29 Start stop button 240Vac 10A 2
30 Indicating light (Bulb ) 240Vac 25W 3
31 Overload Relay 415V 20A 1
32 Three phase dahlander type
induction motor
5 hp 1
33 Single phase step down
transformer
24024Vac
2500VA
1
79 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
34 Single core PVC insulated
Cable
1mm 2 As required
35 Single core PVC insulated
Cable
25mm 2 As required
36 DIN rail 35 mm As required
37 PVC type Cable tray 50 mm x 50 mm As required
38 Cable ties 4 ldquo As required
39 Flexible wires 075 mm As required
40 PVC Connectors 5 A amp 20 A 240 V As required
41 Terminal block 20A 240Vac As required
Procedures
5 Identify each component according to specification and quantity required from the schematic
diagram attached
6 Test the functionality of each component by using multi-meter or power supply whichever
applicable
7 Wire component according to circuit diagram
8 Three motors operated in sequence by DOL starter operated by manual push button or time
delay relay
a One loop per-cycle
b Continuous operation in a loop
c optional circuit design to represent the same task
d Only one out of three motors to be operated at a time (quiz)
9 Test the functionality of completed project
80 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
BASIC DESIGN INDUSTRIAL MOTOR CONTROL (SEQUENCE CONTROL)
THREE PHASE INDUCTION MOTOR OPERATED IN SEQUENCE BY DIRECT ON LINE
STARTER
LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
81 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
82 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Lcd lamp indicator 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
11 Overload Relay 415V 20A 3
12 Three phase induction motor 5 hp 3
13 Single phase step down transformer 2500VA 1
14 Single core PVC insulated Cable 1mm 2 As required
15 Single core PVC insulated Cable 25mm 2 As required
16 DIN rail 35 mm As required
17 PVC type Cable tray 50 mm x 50 mm As required
18 Cable ties 4 ldquo As required
19 Flexible wires 1 mm Oslash As required
20 PVC Terminal block 10A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the schematic
diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a optional exercise
i Forward Reverse dahlander motor
4 Test the functionality of completed project
83 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
THREE PHASE DAHLANDER TYPE INDUCTION MOTOR OPERATED FORWARD AND
REVERSE OPERATION BY DIRECT ON LINE STARTER
84 ndash 99EASYTECH ENTERPRISE
LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
Introduction
If a motors windings are connected in the star configuration any two phases will be in series across
the supply and hence the line current will be smaller(by 577) than if the windings were connected in
the delta arrangement
Hence larger-type motors with heavy starting currents are first connected in star and then when the
starting currents fall in delta This of course means that all six of the ends of the windings must be
brought to terminations outside the casing (Fig 833)
EZTECH
EZTECH ELECTRICAL INSTALLATION GUIDE
The automatic version of this starter incorporates a timing relay which automatically changes the
connections from star to delta Figs 834 and 835 show the wiring and schematic diagrams for a star
delta starter
Objectives
1 Identify component and the specification
2 Design forward reverse star delta starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
2 ndash 99EASYTECH ENTERPRISE
REV -C
LEGENDMCCB Moulded Case Circuit BreakerTOR Thermal Over Load RelayFOW-C Mains Forward ContactorREV-C Mains Reverse ContactorDC Delta ContactorSC Star ContactorS-SW Mains Selector Switch
SC
V2
W2
U2
DC
V1
W1
U1
TOR
TOR
FOW-C
30A MCCB
TOR
MAIN CIRCUIT FORWARD REVERSE STAR DELTA
RYBN S
-SW
3 PHASEINDUCTION MOTOR
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Relay 10 A 240V 3
5 Triple pole Contactor
6 cw NO NC auxiliary contact
240Vac 20 A 4
7 Overload Relay 415 V 1
8 LED indicator 240vac 5 A 4
9 Start stop button 240Vac 5A 2
10 DIN rail 35 mm As required
11 Flexible wires 1 mm As required
12 Single core PVC insulated
wire
25 mm As required
13 Terminal block 20 A As required
14 Squirrel cage motor 5kW 1
15 5 pin plug and socket 415V 20A 1
16 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
3 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
a Manual star delta
b Manual Forward reverse star delta starter
c Automatic star delta starter
d Automatic Forward reverse star delta starter
4 Test the functionality of completed project
4 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
Objectives
1 Identify component and the specification
2 Design auto transformer starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
5 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Autotransformer starter is used to start a 3 phase induction motor that has a rating between 10 to 15 hp
6 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Autotransformer set 10Kw 415 V 50 Hz 1
5 Triple pole Contactor 240Vac 4
6 Batten type Lamp holder 240 Vac 105 A 4
7 Start stop button 240Vac 10A 4
8 Filament lamp (Bulb ) 240Vac 40W 4
9 DIN rail 35 mm As required
10 Flexible wires 1 mm As required
7 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
11 Single core PVC insulated
wire
25 mm As required
12 Terminal block 20 A As required
13 Squirrel cage motor 10kW 1
14 5 pin plug and socket 415V 20A 1
15 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a open transient autotransformer starter
b close transient autotransformer starter
c Forward reverse autotransformer starter
4 Test the functionality of completed project
8 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
Objectives
1 Identify component and the specification
2 Design rotor resistance starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
9 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Rotor Resistor set 10kW 1
5 Triple pole Contactor 240Vac 20A 4
6 Indicating light 240vac 5 A 4
7 Start stop push button 240Vac 5A 4
8 DIN rail 35 mm As required
9 Flexible wires 1 mm 2 As required
10 Single core PVC insulated wire 25 mm 2 As required
11 Terminal block 20 A As required
12 Slip Ring motor 10kW 1
13 5 pin round 3 phase socket 415V 20A 1
14 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
10 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
4 Test the functionality of completed project
a Dead circuit test b Life circuit test
5 Measure starting and running Amps
LESSON 16
TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
An installation in general will suffer damage
Damage usually occurs on the electric motor control as follows
1 Damage to the main circuit
2 Damage to the control circuit
The cause of the damage
i Overcurrent overload short circuit
ii Leakage current to ground
iii Equipment malfunction
iv The main control circuit
a Trip of main circuit protection devices fire
b Defect of motor terminal such as short circuit fire loose
v The control circuit is not functioning -
a contactor relay relay time overload relay does not work damaged burned
b Loose cable connection disconnected
Detecting and Repairing Damage
Examples of damage are as follows
i Motor does not work
ii Motor function and overload relay trips
iii Motor function but only partially functional control circuit
Methods of detecting damage
Among the known methods necessary to detect damage are as follows
1 Turn off the electricity at the main switch (main switch) in order to avoid any danger during the
work carried out to detect damage
2 Check all the protective gear that controls the motor control main circuit
11 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
3 Make sure the damage function control circuit
4 Check the control circuit according to the schematic circuit diagram of the motor control
5 Check the operation of the control circuit
Note
Use wiring that has been installed on the SYSTEM OF MOTOR CONTROL BOARD by Forward
Reverse control circuit for Star Delta to test and look for damage
SELF-ASSESSMENT QUESTIONS
1 (a) Explain what is meant by the term lsquoback emfrsquo in a motor
(b) Outline the basic differences between series shunt and compound wound dc motors
2 (a) With the aid of diagrams explain how the speed of series shunt and compound-wound motors
may be controlled
(b) A 440V dc shunt-wound motor has a field resistance of 200R and an armature resistance of 06 R
When its speed is 20 rev d second the current drawn from the supply is 122A Calculate its back
emf at this speed If the speed were decreased to 19 revssecond the field flux remaining unchanged
calculate the new back emf and the new armature current
3 A load of 64 kW at 240 V is supplied from the terminals of a shunt-wound dc generator The field
resistance is 180 A Calculate the armature current
4 (a) Explain with the aid of a diagram how a rotating magnetic field may be
(b) What is meant by lsquosynchronous speedrsquo
Calculate the synchronous obtained speed of a 12 pole motor if the supply frequency is 50Hz
5 (a) Explain the action of a synchronous motor
(b) What methods are available to start a synchronous motor Explain with diagrams
6 (a) Explain the action of a cage induction motor
(b) What is meant by the term lsquosliprsquo
Calculate the percentage slip of a six pole induction motor running at 162 revssecond from a 50 Hz
supply
7 Describe with sketches three different ways of starting a single-phase induction motor
12 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
8 Explain with the aid of a sketch the action of a three-phase DOL starter
What are dashpots used for How are remote start and stop buttons connected
9 A I0 kW 240V 50Hz single-phase cage rotor induction motor is 85efficient and has a PF of 068
lagging Calculate the motor current and the value of capacitor required to raise the PF to 093
lagging
10 Calculate the torque developed by an 18 kW four-pole induction motor run at 35 slip from a
50Hz supply
APPENDIX 1
13 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 11
14 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 111
Attachment Reference
httpswwwtlc-directcoukBook621htm
httpwwwstgovmyindexphpms
15 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 1
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Lamp point 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
76 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
11 Overload Relay 415V 20A 3
12 Three phase induction
motor
5 hp 3
13 Single core PVC insulated
Cable
1mm 2 As required
14 Single core PVC insulated
Cable
25mm 2 As required
15 DIN rail 35 mm As required
16 PVC type Cable tray 50 mm x 50 mm As required
17 Cable ties 4 ldquo As required
18 Flexible wires 05 mm As required
19 PVC Connectors 5 A amp 20 A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the
schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram optional exercise
4 Simple DOL starter
5 Forward reverse DOL starter
6 Test the functionality of completed project
77 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 1
78 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
cm
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Indicating light 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
11 Overload Relay 415V 20A 3
12 Three phase induction motor 5 hp 3
13 Single phase step down
transformer
2500VA 1
14 Single core PVC insulated
Cable
1mm 2 As required
15 Single core PVC insulated
Cable
25mm 2 As required
16 DIN rail 35 mm As required
17 PVC type Cable tray 50 mm x 50 mm As required
18 Cable ties 4 ldquo As required
19 Flexible wires 05 mm As required
20 PVC Connectors 5 A amp 20 A 240 V As required
21 Single pole MCB 6A 240 V 1
22 Single pole MCB 2A 240 V 1
23 Triple pole MCB 20A 415 V 1
24 Mounting board 30 cm x 40 cm x 3
cm
1
25 Relay cw 11 pin socket 10 A 240 Vac 2
26 Time delay relay 10 A 240 Vac 3
27 Triple pole Contactor 20A 240Vac 3
28 Batten type Lamp holder 240Vac 10 A 3
29 Start stop button 240Vac 10A 2
30 Indicating light (Bulb ) 240Vac 25W 3
31 Overload Relay 415V 20A 1
32 Three phase dahlander type
induction motor
5 hp 1
33 Single phase step down
transformer
24024Vac
2500VA
1
79 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
34 Single core PVC insulated
Cable
1mm 2 As required
35 Single core PVC insulated
Cable
25mm 2 As required
36 DIN rail 35 mm As required
37 PVC type Cable tray 50 mm x 50 mm As required
38 Cable ties 4 ldquo As required
39 Flexible wires 075 mm As required
40 PVC Connectors 5 A amp 20 A 240 V As required
41 Terminal block 20A 240Vac As required
Procedures
5 Identify each component according to specification and quantity required from the schematic
diagram attached
6 Test the functionality of each component by using multi-meter or power supply whichever
applicable
7 Wire component according to circuit diagram
8 Three motors operated in sequence by DOL starter operated by manual push button or time
delay relay
a One loop per-cycle
b Continuous operation in a loop
c optional circuit design to represent the same task
d Only one out of three motors to be operated at a time (quiz)
9 Test the functionality of completed project
80 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
BASIC DESIGN INDUSTRIAL MOTOR CONTROL (SEQUENCE CONTROL)
THREE PHASE INDUCTION MOTOR OPERATED IN SEQUENCE BY DIRECT ON LINE
STARTER
LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
81 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
82 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Lcd lamp indicator 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
11 Overload Relay 415V 20A 3
12 Three phase induction motor 5 hp 3
13 Single phase step down transformer 2500VA 1
14 Single core PVC insulated Cable 1mm 2 As required
15 Single core PVC insulated Cable 25mm 2 As required
16 DIN rail 35 mm As required
17 PVC type Cable tray 50 mm x 50 mm As required
18 Cable ties 4 ldquo As required
19 Flexible wires 1 mm Oslash As required
20 PVC Terminal block 10A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the schematic
diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a optional exercise
i Forward Reverse dahlander motor
4 Test the functionality of completed project
83 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
THREE PHASE DAHLANDER TYPE INDUCTION MOTOR OPERATED FORWARD AND
REVERSE OPERATION BY DIRECT ON LINE STARTER
84 ndash 99EASYTECH ENTERPRISE
LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
Introduction
If a motors windings are connected in the star configuration any two phases will be in series across
the supply and hence the line current will be smaller(by 577) than if the windings were connected in
the delta arrangement
Hence larger-type motors with heavy starting currents are first connected in star and then when the
starting currents fall in delta This of course means that all six of the ends of the windings must be
brought to terminations outside the casing (Fig 833)
EZTECH
EZTECH ELECTRICAL INSTALLATION GUIDE
The automatic version of this starter incorporates a timing relay which automatically changes the
connections from star to delta Figs 834 and 835 show the wiring and schematic diagrams for a star
delta starter
Objectives
1 Identify component and the specification
2 Design forward reverse star delta starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
2 ndash 99EASYTECH ENTERPRISE
REV -C
LEGENDMCCB Moulded Case Circuit BreakerTOR Thermal Over Load RelayFOW-C Mains Forward ContactorREV-C Mains Reverse ContactorDC Delta ContactorSC Star ContactorS-SW Mains Selector Switch
SC
V2
W2
U2
DC
V1
W1
U1
TOR
TOR
FOW-C
30A MCCB
TOR
MAIN CIRCUIT FORWARD REVERSE STAR DELTA
RYBN S
-SW
3 PHASEINDUCTION MOTOR
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Relay 10 A 240V 3
5 Triple pole Contactor
6 cw NO NC auxiliary contact
240Vac 20 A 4
7 Overload Relay 415 V 1
8 LED indicator 240vac 5 A 4
9 Start stop button 240Vac 5A 2
10 DIN rail 35 mm As required
11 Flexible wires 1 mm As required
12 Single core PVC insulated
wire
25 mm As required
13 Terminal block 20 A As required
14 Squirrel cage motor 5kW 1
15 5 pin plug and socket 415V 20A 1
16 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
3 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
a Manual star delta
b Manual Forward reverse star delta starter
c Automatic star delta starter
d Automatic Forward reverse star delta starter
4 Test the functionality of completed project
4 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
Objectives
1 Identify component and the specification
2 Design auto transformer starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
5 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Autotransformer starter is used to start a 3 phase induction motor that has a rating between 10 to 15 hp
6 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Autotransformer set 10Kw 415 V 50 Hz 1
5 Triple pole Contactor 240Vac 4
6 Batten type Lamp holder 240 Vac 105 A 4
7 Start stop button 240Vac 10A 4
8 Filament lamp (Bulb ) 240Vac 40W 4
9 DIN rail 35 mm As required
10 Flexible wires 1 mm As required
7 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
11 Single core PVC insulated
wire
25 mm As required
12 Terminal block 20 A As required
13 Squirrel cage motor 10kW 1
14 5 pin plug and socket 415V 20A 1
15 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a open transient autotransformer starter
b close transient autotransformer starter
c Forward reverse autotransformer starter
4 Test the functionality of completed project
8 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
Objectives
1 Identify component and the specification
2 Design rotor resistance starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
9 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Rotor Resistor set 10kW 1
5 Triple pole Contactor 240Vac 20A 4
6 Indicating light 240vac 5 A 4
7 Start stop push button 240Vac 5A 4
8 DIN rail 35 mm As required
9 Flexible wires 1 mm 2 As required
10 Single core PVC insulated wire 25 mm 2 As required
11 Terminal block 20 A As required
12 Slip Ring motor 10kW 1
13 5 pin round 3 phase socket 415V 20A 1
14 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
10 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
4 Test the functionality of completed project
a Dead circuit test b Life circuit test
5 Measure starting and running Amps
LESSON 16
TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
An installation in general will suffer damage
Damage usually occurs on the electric motor control as follows
1 Damage to the main circuit
2 Damage to the control circuit
The cause of the damage
i Overcurrent overload short circuit
ii Leakage current to ground
iii Equipment malfunction
iv The main control circuit
a Trip of main circuit protection devices fire
b Defect of motor terminal such as short circuit fire loose
v The control circuit is not functioning -
a contactor relay relay time overload relay does not work damaged burned
b Loose cable connection disconnected
Detecting and Repairing Damage
Examples of damage are as follows
i Motor does not work
ii Motor function and overload relay trips
iii Motor function but only partially functional control circuit
Methods of detecting damage
Among the known methods necessary to detect damage are as follows
1 Turn off the electricity at the main switch (main switch) in order to avoid any danger during the
work carried out to detect damage
2 Check all the protective gear that controls the motor control main circuit
11 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
3 Make sure the damage function control circuit
4 Check the control circuit according to the schematic circuit diagram of the motor control
5 Check the operation of the control circuit
Note
Use wiring that has been installed on the SYSTEM OF MOTOR CONTROL BOARD by Forward
Reverse control circuit for Star Delta to test and look for damage
SELF-ASSESSMENT QUESTIONS
1 (a) Explain what is meant by the term lsquoback emfrsquo in a motor
(b) Outline the basic differences between series shunt and compound wound dc motors
2 (a) With the aid of diagrams explain how the speed of series shunt and compound-wound motors
may be controlled
(b) A 440V dc shunt-wound motor has a field resistance of 200R and an armature resistance of 06 R
When its speed is 20 rev d second the current drawn from the supply is 122A Calculate its back
emf at this speed If the speed were decreased to 19 revssecond the field flux remaining unchanged
calculate the new back emf and the new armature current
3 A load of 64 kW at 240 V is supplied from the terminals of a shunt-wound dc generator The field
resistance is 180 A Calculate the armature current
4 (a) Explain with the aid of a diagram how a rotating magnetic field may be
(b) What is meant by lsquosynchronous speedrsquo
Calculate the synchronous obtained speed of a 12 pole motor if the supply frequency is 50Hz
5 (a) Explain the action of a synchronous motor
(b) What methods are available to start a synchronous motor Explain with diagrams
6 (a) Explain the action of a cage induction motor
(b) What is meant by the term lsquosliprsquo
Calculate the percentage slip of a six pole induction motor running at 162 revssecond from a 50 Hz
supply
7 Describe with sketches three different ways of starting a single-phase induction motor
12 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
8 Explain with the aid of a sketch the action of a three-phase DOL starter
What are dashpots used for How are remote start and stop buttons connected
9 A I0 kW 240V 50Hz single-phase cage rotor induction motor is 85efficient and has a PF of 068
lagging Calculate the motor current and the value of capacitor required to raise the PF to 093
lagging
10 Calculate the torque developed by an 18 kW four-pole induction motor run at 35 slip from a
50Hz supply
APPENDIX 1
13 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 11
14 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 111
Attachment Reference
httpswwwtlc-directcoukBook621htm
httpwwwstgovmyindexphpms
15 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
11 Overload Relay 415V 20A 3
12 Three phase induction
motor
5 hp 3
13 Single core PVC insulated
Cable
1mm 2 As required
14 Single core PVC insulated
Cable
25mm 2 As required
15 DIN rail 35 mm As required
16 PVC type Cable tray 50 mm x 50 mm As required
17 Cable ties 4 ldquo As required
18 Flexible wires 05 mm As required
19 PVC Connectors 5 A amp 20 A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the
schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram optional exercise
4 Simple DOL starter
5 Forward reverse DOL starter
6 Test the functionality of completed project
77 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 1
78 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
cm
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Indicating light 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
11 Overload Relay 415V 20A 3
12 Three phase induction motor 5 hp 3
13 Single phase step down
transformer
2500VA 1
14 Single core PVC insulated
Cable
1mm 2 As required
15 Single core PVC insulated
Cable
25mm 2 As required
16 DIN rail 35 mm As required
17 PVC type Cable tray 50 mm x 50 mm As required
18 Cable ties 4 ldquo As required
19 Flexible wires 05 mm As required
20 PVC Connectors 5 A amp 20 A 240 V As required
21 Single pole MCB 6A 240 V 1
22 Single pole MCB 2A 240 V 1
23 Triple pole MCB 20A 415 V 1
24 Mounting board 30 cm x 40 cm x 3
cm
1
25 Relay cw 11 pin socket 10 A 240 Vac 2
26 Time delay relay 10 A 240 Vac 3
27 Triple pole Contactor 20A 240Vac 3
28 Batten type Lamp holder 240Vac 10 A 3
29 Start stop button 240Vac 10A 2
30 Indicating light (Bulb ) 240Vac 25W 3
31 Overload Relay 415V 20A 1
32 Three phase dahlander type
induction motor
5 hp 1
33 Single phase step down
transformer
24024Vac
2500VA
1
79 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
34 Single core PVC insulated
Cable
1mm 2 As required
35 Single core PVC insulated
Cable
25mm 2 As required
36 DIN rail 35 mm As required
37 PVC type Cable tray 50 mm x 50 mm As required
38 Cable ties 4 ldquo As required
39 Flexible wires 075 mm As required
40 PVC Connectors 5 A amp 20 A 240 V As required
41 Terminal block 20A 240Vac As required
Procedures
5 Identify each component according to specification and quantity required from the schematic
diagram attached
6 Test the functionality of each component by using multi-meter or power supply whichever
applicable
7 Wire component according to circuit diagram
8 Three motors operated in sequence by DOL starter operated by manual push button or time
delay relay
a One loop per-cycle
b Continuous operation in a loop
c optional circuit design to represent the same task
d Only one out of three motors to be operated at a time (quiz)
9 Test the functionality of completed project
80 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
BASIC DESIGN INDUSTRIAL MOTOR CONTROL (SEQUENCE CONTROL)
THREE PHASE INDUCTION MOTOR OPERATED IN SEQUENCE BY DIRECT ON LINE
STARTER
LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
81 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
82 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Lcd lamp indicator 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
11 Overload Relay 415V 20A 3
12 Three phase induction motor 5 hp 3
13 Single phase step down transformer 2500VA 1
14 Single core PVC insulated Cable 1mm 2 As required
15 Single core PVC insulated Cable 25mm 2 As required
16 DIN rail 35 mm As required
17 PVC type Cable tray 50 mm x 50 mm As required
18 Cable ties 4 ldquo As required
19 Flexible wires 1 mm Oslash As required
20 PVC Terminal block 10A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the schematic
diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a optional exercise
i Forward Reverse dahlander motor
4 Test the functionality of completed project
83 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
THREE PHASE DAHLANDER TYPE INDUCTION MOTOR OPERATED FORWARD AND
REVERSE OPERATION BY DIRECT ON LINE STARTER
84 ndash 99EASYTECH ENTERPRISE
LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
Introduction
If a motors windings are connected in the star configuration any two phases will be in series across
the supply and hence the line current will be smaller(by 577) than if the windings were connected in
the delta arrangement
Hence larger-type motors with heavy starting currents are first connected in star and then when the
starting currents fall in delta This of course means that all six of the ends of the windings must be
brought to terminations outside the casing (Fig 833)
EZTECH
EZTECH ELECTRICAL INSTALLATION GUIDE
The automatic version of this starter incorporates a timing relay which automatically changes the
connections from star to delta Figs 834 and 835 show the wiring and schematic diagrams for a star
delta starter
Objectives
1 Identify component and the specification
2 Design forward reverse star delta starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
2 ndash 99EASYTECH ENTERPRISE
REV -C
LEGENDMCCB Moulded Case Circuit BreakerTOR Thermal Over Load RelayFOW-C Mains Forward ContactorREV-C Mains Reverse ContactorDC Delta ContactorSC Star ContactorS-SW Mains Selector Switch
SC
V2
W2
U2
DC
V1
W1
U1
TOR
TOR
FOW-C
30A MCCB
TOR
MAIN CIRCUIT FORWARD REVERSE STAR DELTA
RYBN S
-SW
3 PHASEINDUCTION MOTOR
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Relay 10 A 240V 3
5 Triple pole Contactor
6 cw NO NC auxiliary contact
240Vac 20 A 4
7 Overload Relay 415 V 1
8 LED indicator 240vac 5 A 4
9 Start stop button 240Vac 5A 2
10 DIN rail 35 mm As required
11 Flexible wires 1 mm As required
12 Single core PVC insulated
wire
25 mm As required
13 Terminal block 20 A As required
14 Squirrel cage motor 5kW 1
15 5 pin plug and socket 415V 20A 1
16 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
3 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
a Manual star delta
b Manual Forward reverse star delta starter
c Automatic star delta starter
d Automatic Forward reverse star delta starter
4 Test the functionality of completed project
4 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
Objectives
1 Identify component and the specification
2 Design auto transformer starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
5 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Autotransformer starter is used to start a 3 phase induction motor that has a rating between 10 to 15 hp
6 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Autotransformer set 10Kw 415 V 50 Hz 1
5 Triple pole Contactor 240Vac 4
6 Batten type Lamp holder 240 Vac 105 A 4
7 Start stop button 240Vac 10A 4
8 Filament lamp (Bulb ) 240Vac 40W 4
9 DIN rail 35 mm As required
10 Flexible wires 1 mm As required
7 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
11 Single core PVC insulated
wire
25 mm As required
12 Terminal block 20 A As required
13 Squirrel cage motor 10kW 1
14 5 pin plug and socket 415V 20A 1
15 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a open transient autotransformer starter
b close transient autotransformer starter
c Forward reverse autotransformer starter
4 Test the functionality of completed project
8 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
Objectives
1 Identify component and the specification
2 Design rotor resistance starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
9 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Rotor Resistor set 10kW 1
5 Triple pole Contactor 240Vac 20A 4
6 Indicating light 240vac 5 A 4
7 Start stop push button 240Vac 5A 4
8 DIN rail 35 mm As required
9 Flexible wires 1 mm 2 As required
10 Single core PVC insulated wire 25 mm 2 As required
11 Terminal block 20 A As required
12 Slip Ring motor 10kW 1
13 5 pin round 3 phase socket 415V 20A 1
14 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
10 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
4 Test the functionality of completed project
a Dead circuit test b Life circuit test
5 Measure starting and running Amps
LESSON 16
TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
An installation in general will suffer damage
Damage usually occurs on the electric motor control as follows
1 Damage to the main circuit
2 Damage to the control circuit
The cause of the damage
i Overcurrent overload short circuit
ii Leakage current to ground
iii Equipment malfunction
iv The main control circuit
a Trip of main circuit protection devices fire
b Defect of motor terminal such as short circuit fire loose
v The control circuit is not functioning -
a contactor relay relay time overload relay does not work damaged burned
b Loose cable connection disconnected
Detecting and Repairing Damage
Examples of damage are as follows
i Motor does not work
ii Motor function and overload relay trips
iii Motor function but only partially functional control circuit
Methods of detecting damage
Among the known methods necessary to detect damage are as follows
1 Turn off the electricity at the main switch (main switch) in order to avoid any danger during the
work carried out to detect damage
2 Check all the protective gear that controls the motor control main circuit
11 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
3 Make sure the damage function control circuit
4 Check the control circuit according to the schematic circuit diagram of the motor control
5 Check the operation of the control circuit
Note
Use wiring that has been installed on the SYSTEM OF MOTOR CONTROL BOARD by Forward
Reverse control circuit for Star Delta to test and look for damage
SELF-ASSESSMENT QUESTIONS
1 (a) Explain what is meant by the term lsquoback emfrsquo in a motor
(b) Outline the basic differences between series shunt and compound wound dc motors
2 (a) With the aid of diagrams explain how the speed of series shunt and compound-wound motors
may be controlled
(b) A 440V dc shunt-wound motor has a field resistance of 200R and an armature resistance of 06 R
When its speed is 20 rev d second the current drawn from the supply is 122A Calculate its back
emf at this speed If the speed were decreased to 19 revssecond the field flux remaining unchanged
calculate the new back emf and the new armature current
3 A load of 64 kW at 240 V is supplied from the terminals of a shunt-wound dc generator The field
resistance is 180 A Calculate the armature current
4 (a) Explain with the aid of a diagram how a rotating magnetic field may be
(b) What is meant by lsquosynchronous speedrsquo
Calculate the synchronous obtained speed of a 12 pole motor if the supply frequency is 50Hz
5 (a) Explain the action of a synchronous motor
(b) What methods are available to start a synchronous motor Explain with diagrams
6 (a) Explain the action of a cage induction motor
(b) What is meant by the term lsquosliprsquo
Calculate the percentage slip of a six pole induction motor running at 162 revssecond from a 50 Hz
supply
7 Describe with sketches three different ways of starting a single-phase induction motor
12 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
8 Explain with the aid of a sketch the action of a three-phase DOL starter
What are dashpots used for How are remote start and stop buttons connected
9 A I0 kW 240V 50Hz single-phase cage rotor induction motor is 85efficient and has a PF of 068
lagging Calculate the motor current and the value of capacitor required to raise the PF to 093
lagging
10 Calculate the torque developed by an 18 kW four-pole induction motor run at 35 slip from a
50Hz supply
APPENDIX 1
13 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 11
14 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 111
Attachment Reference
httpswwwtlc-directcoukBook621htm
httpwwwstgovmyindexphpms
15 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 1
78 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
cm
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Indicating light 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
11 Overload Relay 415V 20A 3
12 Three phase induction motor 5 hp 3
13 Single phase step down
transformer
2500VA 1
14 Single core PVC insulated
Cable
1mm 2 As required
15 Single core PVC insulated
Cable
25mm 2 As required
16 DIN rail 35 mm As required
17 PVC type Cable tray 50 mm x 50 mm As required
18 Cable ties 4 ldquo As required
19 Flexible wires 05 mm As required
20 PVC Connectors 5 A amp 20 A 240 V As required
21 Single pole MCB 6A 240 V 1
22 Single pole MCB 2A 240 V 1
23 Triple pole MCB 20A 415 V 1
24 Mounting board 30 cm x 40 cm x 3
cm
1
25 Relay cw 11 pin socket 10 A 240 Vac 2
26 Time delay relay 10 A 240 Vac 3
27 Triple pole Contactor 20A 240Vac 3
28 Batten type Lamp holder 240Vac 10 A 3
29 Start stop button 240Vac 10A 2
30 Indicating light (Bulb ) 240Vac 25W 3
31 Overload Relay 415V 20A 1
32 Three phase dahlander type
induction motor
5 hp 1
33 Single phase step down
transformer
24024Vac
2500VA
1
79 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
34 Single core PVC insulated
Cable
1mm 2 As required
35 Single core PVC insulated
Cable
25mm 2 As required
36 DIN rail 35 mm As required
37 PVC type Cable tray 50 mm x 50 mm As required
38 Cable ties 4 ldquo As required
39 Flexible wires 075 mm As required
40 PVC Connectors 5 A amp 20 A 240 V As required
41 Terminal block 20A 240Vac As required
Procedures
5 Identify each component according to specification and quantity required from the schematic
diagram attached
6 Test the functionality of each component by using multi-meter or power supply whichever
applicable
7 Wire component according to circuit diagram
8 Three motors operated in sequence by DOL starter operated by manual push button or time
delay relay
a One loop per-cycle
b Continuous operation in a loop
c optional circuit design to represent the same task
d Only one out of three motors to be operated at a time (quiz)
9 Test the functionality of completed project
80 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
BASIC DESIGN INDUSTRIAL MOTOR CONTROL (SEQUENCE CONTROL)
THREE PHASE INDUCTION MOTOR OPERATED IN SEQUENCE BY DIRECT ON LINE
STARTER
LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
81 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
82 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Lcd lamp indicator 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
11 Overload Relay 415V 20A 3
12 Three phase induction motor 5 hp 3
13 Single phase step down transformer 2500VA 1
14 Single core PVC insulated Cable 1mm 2 As required
15 Single core PVC insulated Cable 25mm 2 As required
16 DIN rail 35 mm As required
17 PVC type Cable tray 50 mm x 50 mm As required
18 Cable ties 4 ldquo As required
19 Flexible wires 1 mm Oslash As required
20 PVC Terminal block 10A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the schematic
diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a optional exercise
i Forward Reverse dahlander motor
4 Test the functionality of completed project
83 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
THREE PHASE DAHLANDER TYPE INDUCTION MOTOR OPERATED FORWARD AND
REVERSE OPERATION BY DIRECT ON LINE STARTER
84 ndash 99EASYTECH ENTERPRISE
LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
Introduction
If a motors windings are connected in the star configuration any two phases will be in series across
the supply and hence the line current will be smaller(by 577) than if the windings were connected in
the delta arrangement
Hence larger-type motors with heavy starting currents are first connected in star and then when the
starting currents fall in delta This of course means that all six of the ends of the windings must be
brought to terminations outside the casing (Fig 833)
EZTECH
EZTECH ELECTRICAL INSTALLATION GUIDE
The automatic version of this starter incorporates a timing relay which automatically changes the
connections from star to delta Figs 834 and 835 show the wiring and schematic diagrams for a star
delta starter
Objectives
1 Identify component and the specification
2 Design forward reverse star delta starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
2 ndash 99EASYTECH ENTERPRISE
REV -C
LEGENDMCCB Moulded Case Circuit BreakerTOR Thermal Over Load RelayFOW-C Mains Forward ContactorREV-C Mains Reverse ContactorDC Delta ContactorSC Star ContactorS-SW Mains Selector Switch
SC
V2
W2
U2
DC
V1
W1
U1
TOR
TOR
FOW-C
30A MCCB
TOR
MAIN CIRCUIT FORWARD REVERSE STAR DELTA
RYBN S
-SW
3 PHASEINDUCTION MOTOR
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Relay 10 A 240V 3
5 Triple pole Contactor
6 cw NO NC auxiliary contact
240Vac 20 A 4
7 Overload Relay 415 V 1
8 LED indicator 240vac 5 A 4
9 Start stop button 240Vac 5A 2
10 DIN rail 35 mm As required
11 Flexible wires 1 mm As required
12 Single core PVC insulated
wire
25 mm As required
13 Terminal block 20 A As required
14 Squirrel cage motor 5kW 1
15 5 pin plug and socket 415V 20A 1
16 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
3 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
a Manual star delta
b Manual Forward reverse star delta starter
c Automatic star delta starter
d Automatic Forward reverse star delta starter
4 Test the functionality of completed project
4 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
Objectives
1 Identify component and the specification
2 Design auto transformer starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
5 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Autotransformer starter is used to start a 3 phase induction motor that has a rating between 10 to 15 hp
6 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Autotransformer set 10Kw 415 V 50 Hz 1
5 Triple pole Contactor 240Vac 4
6 Batten type Lamp holder 240 Vac 105 A 4
7 Start stop button 240Vac 10A 4
8 Filament lamp (Bulb ) 240Vac 40W 4
9 DIN rail 35 mm As required
10 Flexible wires 1 mm As required
7 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
11 Single core PVC insulated
wire
25 mm As required
12 Terminal block 20 A As required
13 Squirrel cage motor 10kW 1
14 5 pin plug and socket 415V 20A 1
15 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a open transient autotransformer starter
b close transient autotransformer starter
c Forward reverse autotransformer starter
4 Test the functionality of completed project
8 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
Objectives
1 Identify component and the specification
2 Design rotor resistance starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
9 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Rotor Resistor set 10kW 1
5 Triple pole Contactor 240Vac 20A 4
6 Indicating light 240vac 5 A 4
7 Start stop push button 240Vac 5A 4
8 DIN rail 35 mm As required
9 Flexible wires 1 mm 2 As required
10 Single core PVC insulated wire 25 mm 2 As required
11 Terminal block 20 A As required
12 Slip Ring motor 10kW 1
13 5 pin round 3 phase socket 415V 20A 1
14 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
10 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
4 Test the functionality of completed project
a Dead circuit test b Life circuit test
5 Measure starting and running Amps
LESSON 16
TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
An installation in general will suffer damage
Damage usually occurs on the electric motor control as follows
1 Damage to the main circuit
2 Damage to the control circuit
The cause of the damage
i Overcurrent overload short circuit
ii Leakage current to ground
iii Equipment malfunction
iv The main control circuit
a Trip of main circuit protection devices fire
b Defect of motor terminal such as short circuit fire loose
v The control circuit is not functioning -
a contactor relay relay time overload relay does not work damaged burned
b Loose cable connection disconnected
Detecting and Repairing Damage
Examples of damage are as follows
i Motor does not work
ii Motor function and overload relay trips
iii Motor function but only partially functional control circuit
Methods of detecting damage
Among the known methods necessary to detect damage are as follows
1 Turn off the electricity at the main switch (main switch) in order to avoid any danger during the
work carried out to detect damage
2 Check all the protective gear that controls the motor control main circuit
11 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
3 Make sure the damage function control circuit
4 Check the control circuit according to the schematic circuit diagram of the motor control
5 Check the operation of the control circuit
Note
Use wiring that has been installed on the SYSTEM OF MOTOR CONTROL BOARD by Forward
Reverse control circuit for Star Delta to test and look for damage
SELF-ASSESSMENT QUESTIONS
1 (a) Explain what is meant by the term lsquoback emfrsquo in a motor
(b) Outline the basic differences between series shunt and compound wound dc motors
2 (a) With the aid of diagrams explain how the speed of series shunt and compound-wound motors
may be controlled
(b) A 440V dc shunt-wound motor has a field resistance of 200R and an armature resistance of 06 R
When its speed is 20 rev d second the current drawn from the supply is 122A Calculate its back
emf at this speed If the speed were decreased to 19 revssecond the field flux remaining unchanged
calculate the new back emf and the new armature current
3 A load of 64 kW at 240 V is supplied from the terminals of a shunt-wound dc generator The field
resistance is 180 A Calculate the armature current
4 (a) Explain with the aid of a diagram how a rotating magnetic field may be
(b) What is meant by lsquosynchronous speedrsquo
Calculate the synchronous obtained speed of a 12 pole motor if the supply frequency is 50Hz
5 (a) Explain the action of a synchronous motor
(b) What methods are available to start a synchronous motor Explain with diagrams
6 (a) Explain the action of a cage induction motor
(b) What is meant by the term lsquosliprsquo
Calculate the percentage slip of a six pole induction motor running at 162 revssecond from a 50 Hz
supply
7 Describe with sketches three different ways of starting a single-phase induction motor
12 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
8 Explain with the aid of a sketch the action of a three-phase DOL starter
What are dashpots used for How are remote start and stop buttons connected
9 A I0 kW 240V 50Hz single-phase cage rotor induction motor is 85efficient and has a PF of 068
lagging Calculate the motor current and the value of capacitor required to raise the PF to 093
lagging
10 Calculate the torque developed by an 18 kW four-pole induction motor run at 35 slip from a
50Hz supply
APPENDIX 1
13 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 11
14 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 111
Attachment Reference
httpswwwtlc-directcoukBook621htm
httpwwwstgovmyindexphpms
15 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
cm
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Indicating light 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
11 Overload Relay 415V 20A 3
12 Three phase induction motor 5 hp 3
13 Single phase step down
transformer
2500VA 1
14 Single core PVC insulated
Cable
1mm 2 As required
15 Single core PVC insulated
Cable
25mm 2 As required
16 DIN rail 35 mm As required
17 PVC type Cable tray 50 mm x 50 mm As required
18 Cable ties 4 ldquo As required
19 Flexible wires 05 mm As required
20 PVC Connectors 5 A amp 20 A 240 V As required
21 Single pole MCB 6A 240 V 1
22 Single pole MCB 2A 240 V 1
23 Triple pole MCB 20A 415 V 1
24 Mounting board 30 cm x 40 cm x 3
cm
1
25 Relay cw 11 pin socket 10 A 240 Vac 2
26 Time delay relay 10 A 240 Vac 3
27 Triple pole Contactor 20A 240Vac 3
28 Batten type Lamp holder 240Vac 10 A 3
29 Start stop button 240Vac 10A 2
30 Indicating light (Bulb ) 240Vac 25W 3
31 Overload Relay 415V 20A 1
32 Three phase dahlander type
induction motor
5 hp 1
33 Single phase step down
transformer
24024Vac
2500VA
1
79 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
34 Single core PVC insulated
Cable
1mm 2 As required
35 Single core PVC insulated
Cable
25mm 2 As required
36 DIN rail 35 mm As required
37 PVC type Cable tray 50 mm x 50 mm As required
38 Cable ties 4 ldquo As required
39 Flexible wires 075 mm As required
40 PVC Connectors 5 A amp 20 A 240 V As required
41 Terminal block 20A 240Vac As required
Procedures
5 Identify each component according to specification and quantity required from the schematic
diagram attached
6 Test the functionality of each component by using multi-meter or power supply whichever
applicable
7 Wire component according to circuit diagram
8 Three motors operated in sequence by DOL starter operated by manual push button or time
delay relay
a One loop per-cycle
b Continuous operation in a loop
c optional circuit design to represent the same task
d Only one out of three motors to be operated at a time (quiz)
9 Test the functionality of completed project
80 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
BASIC DESIGN INDUSTRIAL MOTOR CONTROL (SEQUENCE CONTROL)
THREE PHASE INDUCTION MOTOR OPERATED IN SEQUENCE BY DIRECT ON LINE
STARTER
LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
81 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
82 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Lcd lamp indicator 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
11 Overload Relay 415V 20A 3
12 Three phase induction motor 5 hp 3
13 Single phase step down transformer 2500VA 1
14 Single core PVC insulated Cable 1mm 2 As required
15 Single core PVC insulated Cable 25mm 2 As required
16 DIN rail 35 mm As required
17 PVC type Cable tray 50 mm x 50 mm As required
18 Cable ties 4 ldquo As required
19 Flexible wires 1 mm Oslash As required
20 PVC Terminal block 10A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the schematic
diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a optional exercise
i Forward Reverse dahlander motor
4 Test the functionality of completed project
83 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
THREE PHASE DAHLANDER TYPE INDUCTION MOTOR OPERATED FORWARD AND
REVERSE OPERATION BY DIRECT ON LINE STARTER
84 ndash 99EASYTECH ENTERPRISE
LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
Introduction
If a motors windings are connected in the star configuration any two phases will be in series across
the supply and hence the line current will be smaller(by 577) than if the windings were connected in
the delta arrangement
Hence larger-type motors with heavy starting currents are first connected in star and then when the
starting currents fall in delta This of course means that all six of the ends of the windings must be
brought to terminations outside the casing (Fig 833)
EZTECH
EZTECH ELECTRICAL INSTALLATION GUIDE
The automatic version of this starter incorporates a timing relay which automatically changes the
connections from star to delta Figs 834 and 835 show the wiring and schematic diagrams for a star
delta starter
Objectives
1 Identify component and the specification
2 Design forward reverse star delta starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
2 ndash 99EASYTECH ENTERPRISE
REV -C
LEGENDMCCB Moulded Case Circuit BreakerTOR Thermal Over Load RelayFOW-C Mains Forward ContactorREV-C Mains Reverse ContactorDC Delta ContactorSC Star ContactorS-SW Mains Selector Switch
SC
V2
W2
U2
DC
V1
W1
U1
TOR
TOR
FOW-C
30A MCCB
TOR
MAIN CIRCUIT FORWARD REVERSE STAR DELTA
RYBN S
-SW
3 PHASEINDUCTION MOTOR
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Relay 10 A 240V 3
5 Triple pole Contactor
6 cw NO NC auxiliary contact
240Vac 20 A 4
7 Overload Relay 415 V 1
8 LED indicator 240vac 5 A 4
9 Start stop button 240Vac 5A 2
10 DIN rail 35 mm As required
11 Flexible wires 1 mm As required
12 Single core PVC insulated
wire
25 mm As required
13 Terminal block 20 A As required
14 Squirrel cage motor 5kW 1
15 5 pin plug and socket 415V 20A 1
16 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
3 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
a Manual star delta
b Manual Forward reverse star delta starter
c Automatic star delta starter
d Automatic Forward reverse star delta starter
4 Test the functionality of completed project
4 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
Objectives
1 Identify component and the specification
2 Design auto transformer starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
5 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Autotransformer starter is used to start a 3 phase induction motor that has a rating between 10 to 15 hp
6 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Autotransformer set 10Kw 415 V 50 Hz 1
5 Triple pole Contactor 240Vac 4
6 Batten type Lamp holder 240 Vac 105 A 4
7 Start stop button 240Vac 10A 4
8 Filament lamp (Bulb ) 240Vac 40W 4
9 DIN rail 35 mm As required
10 Flexible wires 1 mm As required
7 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
11 Single core PVC insulated
wire
25 mm As required
12 Terminal block 20 A As required
13 Squirrel cage motor 10kW 1
14 5 pin plug and socket 415V 20A 1
15 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a open transient autotransformer starter
b close transient autotransformer starter
c Forward reverse autotransformer starter
4 Test the functionality of completed project
8 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
Objectives
1 Identify component and the specification
2 Design rotor resistance starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
9 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Rotor Resistor set 10kW 1
5 Triple pole Contactor 240Vac 20A 4
6 Indicating light 240vac 5 A 4
7 Start stop push button 240Vac 5A 4
8 DIN rail 35 mm As required
9 Flexible wires 1 mm 2 As required
10 Single core PVC insulated wire 25 mm 2 As required
11 Terminal block 20 A As required
12 Slip Ring motor 10kW 1
13 5 pin round 3 phase socket 415V 20A 1
14 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
10 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
4 Test the functionality of completed project
a Dead circuit test b Life circuit test
5 Measure starting and running Amps
LESSON 16
TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
An installation in general will suffer damage
Damage usually occurs on the electric motor control as follows
1 Damage to the main circuit
2 Damage to the control circuit
The cause of the damage
i Overcurrent overload short circuit
ii Leakage current to ground
iii Equipment malfunction
iv The main control circuit
a Trip of main circuit protection devices fire
b Defect of motor terminal such as short circuit fire loose
v The control circuit is not functioning -
a contactor relay relay time overload relay does not work damaged burned
b Loose cable connection disconnected
Detecting and Repairing Damage
Examples of damage are as follows
i Motor does not work
ii Motor function and overload relay trips
iii Motor function but only partially functional control circuit
Methods of detecting damage
Among the known methods necessary to detect damage are as follows
1 Turn off the electricity at the main switch (main switch) in order to avoid any danger during the
work carried out to detect damage
2 Check all the protective gear that controls the motor control main circuit
11 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
3 Make sure the damage function control circuit
4 Check the control circuit according to the schematic circuit diagram of the motor control
5 Check the operation of the control circuit
Note
Use wiring that has been installed on the SYSTEM OF MOTOR CONTROL BOARD by Forward
Reverse control circuit for Star Delta to test and look for damage
SELF-ASSESSMENT QUESTIONS
1 (a) Explain what is meant by the term lsquoback emfrsquo in a motor
(b) Outline the basic differences between series shunt and compound wound dc motors
2 (a) With the aid of diagrams explain how the speed of series shunt and compound-wound motors
may be controlled
(b) A 440V dc shunt-wound motor has a field resistance of 200R and an armature resistance of 06 R
When its speed is 20 rev d second the current drawn from the supply is 122A Calculate its back
emf at this speed If the speed were decreased to 19 revssecond the field flux remaining unchanged
calculate the new back emf and the new armature current
3 A load of 64 kW at 240 V is supplied from the terminals of a shunt-wound dc generator The field
resistance is 180 A Calculate the armature current
4 (a) Explain with the aid of a diagram how a rotating magnetic field may be
(b) What is meant by lsquosynchronous speedrsquo
Calculate the synchronous obtained speed of a 12 pole motor if the supply frequency is 50Hz
5 (a) Explain the action of a synchronous motor
(b) What methods are available to start a synchronous motor Explain with diagrams
6 (a) Explain the action of a cage induction motor
(b) What is meant by the term lsquosliprsquo
Calculate the percentage slip of a six pole induction motor running at 162 revssecond from a 50 Hz
supply
7 Describe with sketches three different ways of starting a single-phase induction motor
12 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
8 Explain with the aid of a sketch the action of a three-phase DOL starter
What are dashpots used for How are remote start and stop buttons connected
9 A I0 kW 240V 50Hz single-phase cage rotor induction motor is 85efficient and has a PF of 068
lagging Calculate the motor current and the value of capacitor required to raise the PF to 093
lagging
10 Calculate the torque developed by an 18 kW four-pole induction motor run at 35 slip from a
50Hz supply
APPENDIX 1
13 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 11
14 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 111
Attachment Reference
httpswwwtlc-directcoukBook621htm
httpwwwstgovmyindexphpms
15 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
34 Single core PVC insulated
Cable
1mm 2 As required
35 Single core PVC insulated
Cable
25mm 2 As required
36 DIN rail 35 mm As required
37 PVC type Cable tray 50 mm x 50 mm As required
38 Cable ties 4 ldquo As required
39 Flexible wires 075 mm As required
40 PVC Connectors 5 A amp 20 A 240 V As required
41 Terminal block 20A 240Vac As required
Procedures
5 Identify each component according to specification and quantity required from the schematic
diagram attached
6 Test the functionality of each component by using multi-meter or power supply whichever
applicable
7 Wire component according to circuit diagram
8 Three motors operated in sequence by DOL starter operated by manual push button or time
delay relay
a One loop per-cycle
b Continuous operation in a loop
c optional circuit design to represent the same task
d Only one out of three motors to be operated at a time (quiz)
9 Test the functionality of completed project
80 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
BASIC DESIGN INDUSTRIAL MOTOR CONTROL (SEQUENCE CONTROL)
THREE PHASE INDUCTION MOTOR OPERATED IN SEQUENCE BY DIRECT ON LINE
STARTER
LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
81 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
82 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Lcd lamp indicator 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
11 Overload Relay 415V 20A 3
12 Three phase induction motor 5 hp 3
13 Single phase step down transformer 2500VA 1
14 Single core PVC insulated Cable 1mm 2 As required
15 Single core PVC insulated Cable 25mm 2 As required
16 DIN rail 35 mm As required
17 PVC type Cable tray 50 mm x 50 mm As required
18 Cable ties 4 ldquo As required
19 Flexible wires 1 mm Oslash As required
20 PVC Terminal block 10A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the schematic
diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a optional exercise
i Forward Reverse dahlander motor
4 Test the functionality of completed project
83 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
THREE PHASE DAHLANDER TYPE INDUCTION MOTOR OPERATED FORWARD AND
REVERSE OPERATION BY DIRECT ON LINE STARTER
84 ndash 99EASYTECH ENTERPRISE
LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
Introduction
If a motors windings are connected in the star configuration any two phases will be in series across
the supply and hence the line current will be smaller(by 577) than if the windings were connected in
the delta arrangement
Hence larger-type motors with heavy starting currents are first connected in star and then when the
starting currents fall in delta This of course means that all six of the ends of the windings must be
brought to terminations outside the casing (Fig 833)
EZTECH
EZTECH ELECTRICAL INSTALLATION GUIDE
The automatic version of this starter incorporates a timing relay which automatically changes the
connections from star to delta Figs 834 and 835 show the wiring and schematic diagrams for a star
delta starter
Objectives
1 Identify component and the specification
2 Design forward reverse star delta starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
2 ndash 99EASYTECH ENTERPRISE
REV -C
LEGENDMCCB Moulded Case Circuit BreakerTOR Thermal Over Load RelayFOW-C Mains Forward ContactorREV-C Mains Reverse ContactorDC Delta ContactorSC Star ContactorS-SW Mains Selector Switch
SC
V2
W2
U2
DC
V1
W1
U1
TOR
TOR
FOW-C
30A MCCB
TOR
MAIN CIRCUIT FORWARD REVERSE STAR DELTA
RYBN S
-SW
3 PHASEINDUCTION MOTOR
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Relay 10 A 240V 3
5 Triple pole Contactor
6 cw NO NC auxiliary contact
240Vac 20 A 4
7 Overload Relay 415 V 1
8 LED indicator 240vac 5 A 4
9 Start stop button 240Vac 5A 2
10 DIN rail 35 mm As required
11 Flexible wires 1 mm As required
12 Single core PVC insulated
wire
25 mm As required
13 Terminal block 20 A As required
14 Squirrel cage motor 5kW 1
15 5 pin plug and socket 415V 20A 1
16 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
3 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
a Manual star delta
b Manual Forward reverse star delta starter
c Automatic star delta starter
d Automatic Forward reverse star delta starter
4 Test the functionality of completed project
4 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
Objectives
1 Identify component and the specification
2 Design auto transformer starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
5 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Autotransformer starter is used to start a 3 phase induction motor that has a rating between 10 to 15 hp
6 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Autotransformer set 10Kw 415 V 50 Hz 1
5 Triple pole Contactor 240Vac 4
6 Batten type Lamp holder 240 Vac 105 A 4
7 Start stop button 240Vac 10A 4
8 Filament lamp (Bulb ) 240Vac 40W 4
9 DIN rail 35 mm As required
10 Flexible wires 1 mm As required
7 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
11 Single core PVC insulated
wire
25 mm As required
12 Terminal block 20 A As required
13 Squirrel cage motor 10kW 1
14 5 pin plug and socket 415V 20A 1
15 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a open transient autotransformer starter
b close transient autotransformer starter
c Forward reverse autotransformer starter
4 Test the functionality of completed project
8 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
Objectives
1 Identify component and the specification
2 Design rotor resistance starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
9 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Rotor Resistor set 10kW 1
5 Triple pole Contactor 240Vac 20A 4
6 Indicating light 240vac 5 A 4
7 Start stop push button 240Vac 5A 4
8 DIN rail 35 mm As required
9 Flexible wires 1 mm 2 As required
10 Single core PVC insulated wire 25 mm 2 As required
11 Terminal block 20 A As required
12 Slip Ring motor 10kW 1
13 5 pin round 3 phase socket 415V 20A 1
14 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
10 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
4 Test the functionality of completed project
a Dead circuit test b Life circuit test
5 Measure starting and running Amps
LESSON 16
TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
An installation in general will suffer damage
Damage usually occurs on the electric motor control as follows
1 Damage to the main circuit
2 Damage to the control circuit
The cause of the damage
i Overcurrent overload short circuit
ii Leakage current to ground
iii Equipment malfunction
iv The main control circuit
a Trip of main circuit protection devices fire
b Defect of motor terminal such as short circuit fire loose
v The control circuit is not functioning -
a contactor relay relay time overload relay does not work damaged burned
b Loose cable connection disconnected
Detecting and Repairing Damage
Examples of damage are as follows
i Motor does not work
ii Motor function and overload relay trips
iii Motor function but only partially functional control circuit
Methods of detecting damage
Among the known methods necessary to detect damage are as follows
1 Turn off the electricity at the main switch (main switch) in order to avoid any danger during the
work carried out to detect damage
2 Check all the protective gear that controls the motor control main circuit
11 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
3 Make sure the damage function control circuit
4 Check the control circuit according to the schematic circuit diagram of the motor control
5 Check the operation of the control circuit
Note
Use wiring that has been installed on the SYSTEM OF MOTOR CONTROL BOARD by Forward
Reverse control circuit for Star Delta to test and look for damage
SELF-ASSESSMENT QUESTIONS
1 (a) Explain what is meant by the term lsquoback emfrsquo in a motor
(b) Outline the basic differences between series shunt and compound wound dc motors
2 (a) With the aid of diagrams explain how the speed of series shunt and compound-wound motors
may be controlled
(b) A 440V dc shunt-wound motor has a field resistance of 200R and an armature resistance of 06 R
When its speed is 20 rev d second the current drawn from the supply is 122A Calculate its back
emf at this speed If the speed were decreased to 19 revssecond the field flux remaining unchanged
calculate the new back emf and the new armature current
3 A load of 64 kW at 240 V is supplied from the terminals of a shunt-wound dc generator The field
resistance is 180 A Calculate the armature current
4 (a) Explain with the aid of a diagram how a rotating magnetic field may be
(b) What is meant by lsquosynchronous speedrsquo
Calculate the synchronous obtained speed of a 12 pole motor if the supply frequency is 50Hz
5 (a) Explain the action of a synchronous motor
(b) What methods are available to start a synchronous motor Explain with diagrams
6 (a) Explain the action of a cage induction motor
(b) What is meant by the term lsquosliprsquo
Calculate the percentage slip of a six pole induction motor running at 162 revssecond from a 50 Hz
supply
7 Describe with sketches three different ways of starting a single-phase induction motor
12 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
8 Explain with the aid of a sketch the action of a three-phase DOL starter
What are dashpots used for How are remote start and stop buttons connected
9 A I0 kW 240V 50Hz single-phase cage rotor induction motor is 85efficient and has a PF of 068
lagging Calculate the motor current and the value of capacitor required to raise the PF to 093
lagging
10 Calculate the torque developed by an 18 kW four-pole induction motor run at 35 slip from a
50Hz supply
APPENDIX 1
13 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 11
14 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 111
Attachment Reference
httpswwwtlc-directcoukBook621htm
httpwwwstgovmyindexphpms
15 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
BASIC DESIGN INDUSTRIAL MOTOR CONTROL (SEQUENCE CONTROL)
THREE PHASE INDUCTION MOTOR OPERATED IN SEQUENCE BY DIRECT ON LINE
STARTER
LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
81 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
82 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Lcd lamp indicator 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
11 Overload Relay 415V 20A 3
12 Three phase induction motor 5 hp 3
13 Single phase step down transformer 2500VA 1
14 Single core PVC insulated Cable 1mm 2 As required
15 Single core PVC insulated Cable 25mm 2 As required
16 DIN rail 35 mm As required
17 PVC type Cable tray 50 mm x 50 mm As required
18 Cable ties 4 ldquo As required
19 Flexible wires 1 mm Oslash As required
20 PVC Terminal block 10A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the schematic
diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a optional exercise
i Forward Reverse dahlander motor
4 Test the functionality of completed project
83 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
THREE PHASE DAHLANDER TYPE INDUCTION MOTOR OPERATED FORWARD AND
REVERSE OPERATION BY DIRECT ON LINE STARTER
84 ndash 99EASYTECH ENTERPRISE
LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
Introduction
If a motors windings are connected in the star configuration any two phases will be in series across
the supply and hence the line current will be smaller(by 577) than if the windings were connected in
the delta arrangement
Hence larger-type motors with heavy starting currents are first connected in star and then when the
starting currents fall in delta This of course means that all six of the ends of the windings must be
brought to terminations outside the casing (Fig 833)
EZTECH
EZTECH ELECTRICAL INSTALLATION GUIDE
The automatic version of this starter incorporates a timing relay which automatically changes the
connections from star to delta Figs 834 and 835 show the wiring and schematic diagrams for a star
delta starter
Objectives
1 Identify component and the specification
2 Design forward reverse star delta starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
2 ndash 99EASYTECH ENTERPRISE
REV -C
LEGENDMCCB Moulded Case Circuit BreakerTOR Thermal Over Load RelayFOW-C Mains Forward ContactorREV-C Mains Reverse ContactorDC Delta ContactorSC Star ContactorS-SW Mains Selector Switch
SC
V2
W2
U2
DC
V1
W1
U1
TOR
TOR
FOW-C
30A MCCB
TOR
MAIN CIRCUIT FORWARD REVERSE STAR DELTA
RYBN S
-SW
3 PHASEINDUCTION MOTOR
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Relay 10 A 240V 3
5 Triple pole Contactor
6 cw NO NC auxiliary contact
240Vac 20 A 4
7 Overload Relay 415 V 1
8 LED indicator 240vac 5 A 4
9 Start stop button 240Vac 5A 2
10 DIN rail 35 mm As required
11 Flexible wires 1 mm As required
12 Single core PVC insulated
wire
25 mm As required
13 Terminal block 20 A As required
14 Squirrel cage motor 5kW 1
15 5 pin plug and socket 415V 20A 1
16 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
3 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
a Manual star delta
b Manual Forward reverse star delta starter
c Automatic star delta starter
d Automatic Forward reverse star delta starter
4 Test the functionality of completed project
4 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
Objectives
1 Identify component and the specification
2 Design auto transformer starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
5 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Autotransformer starter is used to start a 3 phase induction motor that has a rating between 10 to 15 hp
6 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Autotransformer set 10Kw 415 V 50 Hz 1
5 Triple pole Contactor 240Vac 4
6 Batten type Lamp holder 240 Vac 105 A 4
7 Start stop button 240Vac 10A 4
8 Filament lamp (Bulb ) 240Vac 40W 4
9 DIN rail 35 mm As required
10 Flexible wires 1 mm As required
7 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
11 Single core PVC insulated
wire
25 mm As required
12 Terminal block 20 A As required
13 Squirrel cage motor 10kW 1
14 5 pin plug and socket 415V 20A 1
15 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a open transient autotransformer starter
b close transient autotransformer starter
c Forward reverse autotransformer starter
4 Test the functionality of completed project
8 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
Objectives
1 Identify component and the specification
2 Design rotor resistance starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
9 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Rotor Resistor set 10kW 1
5 Triple pole Contactor 240Vac 20A 4
6 Indicating light 240vac 5 A 4
7 Start stop push button 240Vac 5A 4
8 DIN rail 35 mm As required
9 Flexible wires 1 mm 2 As required
10 Single core PVC insulated wire 25 mm 2 As required
11 Terminal block 20 A As required
12 Slip Ring motor 10kW 1
13 5 pin round 3 phase socket 415V 20A 1
14 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
10 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
4 Test the functionality of completed project
a Dead circuit test b Life circuit test
5 Measure starting and running Amps
LESSON 16
TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
An installation in general will suffer damage
Damage usually occurs on the electric motor control as follows
1 Damage to the main circuit
2 Damage to the control circuit
The cause of the damage
i Overcurrent overload short circuit
ii Leakage current to ground
iii Equipment malfunction
iv The main control circuit
a Trip of main circuit protection devices fire
b Defect of motor terminal such as short circuit fire loose
v The control circuit is not functioning -
a contactor relay relay time overload relay does not work damaged burned
b Loose cable connection disconnected
Detecting and Repairing Damage
Examples of damage are as follows
i Motor does not work
ii Motor function and overload relay trips
iii Motor function but only partially functional control circuit
Methods of detecting damage
Among the known methods necessary to detect damage are as follows
1 Turn off the electricity at the main switch (main switch) in order to avoid any danger during the
work carried out to detect damage
2 Check all the protective gear that controls the motor control main circuit
11 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
3 Make sure the damage function control circuit
4 Check the control circuit according to the schematic circuit diagram of the motor control
5 Check the operation of the control circuit
Note
Use wiring that has been installed on the SYSTEM OF MOTOR CONTROL BOARD by Forward
Reverse control circuit for Star Delta to test and look for damage
SELF-ASSESSMENT QUESTIONS
1 (a) Explain what is meant by the term lsquoback emfrsquo in a motor
(b) Outline the basic differences between series shunt and compound wound dc motors
2 (a) With the aid of diagrams explain how the speed of series shunt and compound-wound motors
may be controlled
(b) A 440V dc shunt-wound motor has a field resistance of 200R and an armature resistance of 06 R
When its speed is 20 rev d second the current drawn from the supply is 122A Calculate its back
emf at this speed If the speed were decreased to 19 revssecond the field flux remaining unchanged
calculate the new back emf and the new armature current
3 A load of 64 kW at 240 V is supplied from the terminals of a shunt-wound dc generator The field
resistance is 180 A Calculate the armature current
4 (a) Explain with the aid of a diagram how a rotating magnetic field may be
(b) What is meant by lsquosynchronous speedrsquo
Calculate the synchronous obtained speed of a 12 pole motor if the supply frequency is 50Hz
5 (a) Explain the action of a synchronous motor
(b) What methods are available to start a synchronous motor Explain with diagrams
6 (a) Explain the action of a cage induction motor
(b) What is meant by the term lsquosliprsquo
Calculate the percentage slip of a six pole induction motor running at 162 revssecond from a 50 Hz
supply
7 Describe with sketches three different ways of starting a single-phase induction motor
12 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
8 Explain with the aid of a sketch the action of a three-phase DOL starter
What are dashpots used for How are remote start and stop buttons connected
9 A I0 kW 240V 50Hz single-phase cage rotor induction motor is 85efficient and has a PF of 068
lagging Calculate the motor current and the value of capacitor required to raise the PF to 093
lagging
10 Calculate the torque developed by an 18 kW four-pole induction motor run at 35 slip from a
50Hz supply
APPENDIX 1
13 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 11
14 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 111
Attachment Reference
httpswwwtlc-directcoukBook621htm
httpwwwstgovmyindexphpms
15 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Objectives
1 Identify component and the specification
2 Design Direct on line starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
82 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Lcd lamp indicator 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
11 Overload Relay 415V 20A 3
12 Three phase induction motor 5 hp 3
13 Single phase step down transformer 2500VA 1
14 Single core PVC insulated Cable 1mm 2 As required
15 Single core PVC insulated Cable 25mm 2 As required
16 DIN rail 35 mm As required
17 PVC type Cable tray 50 mm x 50 mm As required
18 Cable ties 4 ldquo As required
19 Flexible wires 1 mm Oslash As required
20 PVC Terminal block 10A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the schematic
diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a optional exercise
i Forward Reverse dahlander motor
4 Test the functionality of completed project
83 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
THREE PHASE DAHLANDER TYPE INDUCTION MOTOR OPERATED FORWARD AND
REVERSE OPERATION BY DIRECT ON LINE STARTER
84 ndash 99EASYTECH ENTERPRISE
LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
Introduction
If a motors windings are connected in the star configuration any two phases will be in series across
the supply and hence the line current will be smaller(by 577) than if the windings were connected in
the delta arrangement
Hence larger-type motors with heavy starting currents are first connected in star and then when the
starting currents fall in delta This of course means that all six of the ends of the windings must be
brought to terminations outside the casing (Fig 833)
EZTECH
EZTECH ELECTRICAL INSTALLATION GUIDE
The automatic version of this starter incorporates a timing relay which automatically changes the
connections from star to delta Figs 834 and 835 show the wiring and schematic diagrams for a star
delta starter
Objectives
1 Identify component and the specification
2 Design forward reverse star delta starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
2 ndash 99EASYTECH ENTERPRISE
REV -C
LEGENDMCCB Moulded Case Circuit BreakerTOR Thermal Over Load RelayFOW-C Mains Forward ContactorREV-C Mains Reverse ContactorDC Delta ContactorSC Star ContactorS-SW Mains Selector Switch
SC
V2
W2
U2
DC
V1
W1
U1
TOR
TOR
FOW-C
30A MCCB
TOR
MAIN CIRCUIT FORWARD REVERSE STAR DELTA
RYBN S
-SW
3 PHASEINDUCTION MOTOR
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Relay 10 A 240V 3
5 Triple pole Contactor
6 cw NO NC auxiliary contact
240Vac 20 A 4
7 Overload Relay 415 V 1
8 LED indicator 240vac 5 A 4
9 Start stop button 240Vac 5A 2
10 DIN rail 35 mm As required
11 Flexible wires 1 mm As required
12 Single core PVC insulated
wire
25 mm As required
13 Terminal block 20 A As required
14 Squirrel cage motor 5kW 1
15 5 pin plug and socket 415V 20A 1
16 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
3 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
a Manual star delta
b Manual Forward reverse star delta starter
c Automatic star delta starter
d Automatic Forward reverse star delta starter
4 Test the functionality of completed project
4 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
Objectives
1 Identify component and the specification
2 Design auto transformer starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
5 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Autotransformer starter is used to start a 3 phase induction motor that has a rating between 10 to 15 hp
6 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Autotransformer set 10Kw 415 V 50 Hz 1
5 Triple pole Contactor 240Vac 4
6 Batten type Lamp holder 240 Vac 105 A 4
7 Start stop button 240Vac 10A 4
8 Filament lamp (Bulb ) 240Vac 40W 4
9 DIN rail 35 mm As required
10 Flexible wires 1 mm As required
7 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
11 Single core PVC insulated
wire
25 mm As required
12 Terminal block 20 A As required
13 Squirrel cage motor 10kW 1
14 5 pin plug and socket 415V 20A 1
15 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a open transient autotransformer starter
b close transient autotransformer starter
c Forward reverse autotransformer starter
4 Test the functionality of completed project
8 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
Objectives
1 Identify component and the specification
2 Design rotor resistance starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
9 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Rotor Resistor set 10kW 1
5 Triple pole Contactor 240Vac 20A 4
6 Indicating light 240vac 5 A 4
7 Start stop push button 240Vac 5A 4
8 DIN rail 35 mm As required
9 Flexible wires 1 mm 2 As required
10 Single core PVC insulated wire 25 mm 2 As required
11 Terminal block 20 A As required
12 Slip Ring motor 10kW 1
13 5 pin round 3 phase socket 415V 20A 1
14 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
10 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
4 Test the functionality of completed project
a Dead circuit test b Life circuit test
5 Measure starting and running Amps
LESSON 16
TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
An installation in general will suffer damage
Damage usually occurs on the electric motor control as follows
1 Damage to the main circuit
2 Damage to the control circuit
The cause of the damage
i Overcurrent overload short circuit
ii Leakage current to ground
iii Equipment malfunction
iv The main control circuit
a Trip of main circuit protection devices fire
b Defect of motor terminal such as short circuit fire loose
v The control circuit is not functioning -
a contactor relay relay time overload relay does not work damaged burned
b Loose cable connection disconnected
Detecting and Repairing Damage
Examples of damage are as follows
i Motor does not work
ii Motor function and overload relay trips
iii Motor function but only partially functional control circuit
Methods of detecting damage
Among the known methods necessary to detect damage are as follows
1 Turn off the electricity at the main switch (main switch) in order to avoid any danger during the
work carried out to detect damage
2 Check all the protective gear that controls the motor control main circuit
11 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
3 Make sure the damage function control circuit
4 Check the control circuit according to the schematic circuit diagram of the motor control
5 Check the operation of the control circuit
Note
Use wiring that has been installed on the SYSTEM OF MOTOR CONTROL BOARD by Forward
Reverse control circuit for Star Delta to test and look for damage
SELF-ASSESSMENT QUESTIONS
1 (a) Explain what is meant by the term lsquoback emfrsquo in a motor
(b) Outline the basic differences between series shunt and compound wound dc motors
2 (a) With the aid of diagrams explain how the speed of series shunt and compound-wound motors
may be controlled
(b) A 440V dc shunt-wound motor has a field resistance of 200R and an armature resistance of 06 R
When its speed is 20 rev d second the current drawn from the supply is 122A Calculate its back
emf at this speed If the speed were decreased to 19 revssecond the field flux remaining unchanged
calculate the new back emf and the new armature current
3 A load of 64 kW at 240 V is supplied from the terminals of a shunt-wound dc generator The field
resistance is 180 A Calculate the armature current
4 (a) Explain with the aid of a diagram how a rotating magnetic field may be
(b) What is meant by lsquosynchronous speedrsquo
Calculate the synchronous obtained speed of a 12 pole motor if the supply frequency is 50Hz
5 (a) Explain the action of a synchronous motor
(b) What methods are available to start a synchronous motor Explain with diagrams
6 (a) Explain the action of a cage induction motor
(b) What is meant by the term lsquosliprsquo
Calculate the percentage slip of a six pole induction motor running at 162 revssecond from a 50 Hz
supply
7 Describe with sketches three different ways of starting a single-phase induction motor
12 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
8 Explain with the aid of a sketch the action of a three-phase DOL starter
What are dashpots used for How are remote start and stop buttons connected
9 A I0 kW 240V 50Hz single-phase cage rotor induction motor is 85efficient and has a PF of 068
lagging Calculate the motor current and the value of capacitor required to raise the PF to 093
lagging
10 Calculate the torque developed by an 18 kW four-pole induction motor run at 35 slip from a
50Hz supply
APPENDIX 1
13 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 11
14 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 111
Attachment Reference
httpswwwtlc-directcoukBook621htm
httpwwwstgovmyindexphpms
15 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Single pole MCB 6A 240 V 1
2 Single pole MCB 2A 240 V 1
3 Triple pole MCB 20A 415 V 3
4 Mounting board 30 cm x 40 cm x 3 cm 1
5 Relay cw 11 pin socket 10 A 240 Vac 4
6 Time delay relay 10 A 240 Vac 3
7 Triple pole Contactor 20A 240Vac 3
8 Lcd lamp indicator 240Vac 5 A 3
9 Start stop button 240Vac 5A 2
10 Filament lamp (Bulb ) 240Vac 40W 3
11 Overload Relay 415V 20A 3
12 Three phase induction motor 5 hp 3
13 Single phase step down transformer 2500VA 1
14 Single core PVC insulated Cable 1mm 2 As required
15 Single core PVC insulated Cable 25mm 2 As required
16 DIN rail 35 mm As required
17 PVC type Cable tray 50 mm x 50 mm As required
18 Cable ties 4 ldquo As required
19 Flexible wires 1 mm Oslash As required
20 PVC Terminal block 10A 240 V As required
Procedures
1 Identify each component according to specification and quantity required from the schematic
diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a optional exercise
i Forward Reverse dahlander motor
4 Test the functionality of completed project
83 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
THREE PHASE DAHLANDER TYPE INDUCTION MOTOR OPERATED FORWARD AND
REVERSE OPERATION BY DIRECT ON LINE STARTER
84 ndash 99EASYTECH ENTERPRISE
LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
Introduction
If a motors windings are connected in the star configuration any two phases will be in series across
the supply and hence the line current will be smaller(by 577) than if the windings were connected in
the delta arrangement
Hence larger-type motors with heavy starting currents are first connected in star and then when the
starting currents fall in delta This of course means that all six of the ends of the windings must be
brought to terminations outside the casing (Fig 833)
EZTECH
EZTECH ELECTRICAL INSTALLATION GUIDE
The automatic version of this starter incorporates a timing relay which automatically changes the
connections from star to delta Figs 834 and 835 show the wiring and schematic diagrams for a star
delta starter
Objectives
1 Identify component and the specification
2 Design forward reverse star delta starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
2 ndash 99EASYTECH ENTERPRISE
REV -C
LEGENDMCCB Moulded Case Circuit BreakerTOR Thermal Over Load RelayFOW-C Mains Forward ContactorREV-C Mains Reverse ContactorDC Delta ContactorSC Star ContactorS-SW Mains Selector Switch
SC
V2
W2
U2
DC
V1
W1
U1
TOR
TOR
FOW-C
30A MCCB
TOR
MAIN CIRCUIT FORWARD REVERSE STAR DELTA
RYBN S
-SW
3 PHASEINDUCTION MOTOR
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Relay 10 A 240V 3
5 Triple pole Contactor
6 cw NO NC auxiliary contact
240Vac 20 A 4
7 Overload Relay 415 V 1
8 LED indicator 240vac 5 A 4
9 Start stop button 240Vac 5A 2
10 DIN rail 35 mm As required
11 Flexible wires 1 mm As required
12 Single core PVC insulated
wire
25 mm As required
13 Terminal block 20 A As required
14 Squirrel cage motor 5kW 1
15 5 pin plug and socket 415V 20A 1
16 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
3 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
a Manual star delta
b Manual Forward reverse star delta starter
c Automatic star delta starter
d Automatic Forward reverse star delta starter
4 Test the functionality of completed project
4 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
Objectives
1 Identify component and the specification
2 Design auto transformer starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
5 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Autotransformer starter is used to start a 3 phase induction motor that has a rating between 10 to 15 hp
6 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Autotransformer set 10Kw 415 V 50 Hz 1
5 Triple pole Contactor 240Vac 4
6 Batten type Lamp holder 240 Vac 105 A 4
7 Start stop button 240Vac 10A 4
8 Filament lamp (Bulb ) 240Vac 40W 4
9 DIN rail 35 mm As required
10 Flexible wires 1 mm As required
7 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
11 Single core PVC insulated
wire
25 mm As required
12 Terminal block 20 A As required
13 Squirrel cage motor 10kW 1
14 5 pin plug and socket 415V 20A 1
15 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a open transient autotransformer starter
b close transient autotransformer starter
c Forward reverse autotransformer starter
4 Test the functionality of completed project
8 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
Objectives
1 Identify component and the specification
2 Design rotor resistance starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
9 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Rotor Resistor set 10kW 1
5 Triple pole Contactor 240Vac 20A 4
6 Indicating light 240vac 5 A 4
7 Start stop push button 240Vac 5A 4
8 DIN rail 35 mm As required
9 Flexible wires 1 mm 2 As required
10 Single core PVC insulated wire 25 mm 2 As required
11 Terminal block 20 A As required
12 Slip Ring motor 10kW 1
13 5 pin round 3 phase socket 415V 20A 1
14 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
10 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
4 Test the functionality of completed project
a Dead circuit test b Life circuit test
5 Measure starting and running Amps
LESSON 16
TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
An installation in general will suffer damage
Damage usually occurs on the electric motor control as follows
1 Damage to the main circuit
2 Damage to the control circuit
The cause of the damage
i Overcurrent overload short circuit
ii Leakage current to ground
iii Equipment malfunction
iv The main control circuit
a Trip of main circuit protection devices fire
b Defect of motor terminal such as short circuit fire loose
v The control circuit is not functioning -
a contactor relay relay time overload relay does not work damaged burned
b Loose cable connection disconnected
Detecting and Repairing Damage
Examples of damage are as follows
i Motor does not work
ii Motor function and overload relay trips
iii Motor function but only partially functional control circuit
Methods of detecting damage
Among the known methods necessary to detect damage are as follows
1 Turn off the electricity at the main switch (main switch) in order to avoid any danger during the
work carried out to detect damage
2 Check all the protective gear that controls the motor control main circuit
11 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
3 Make sure the damage function control circuit
4 Check the control circuit according to the schematic circuit diagram of the motor control
5 Check the operation of the control circuit
Note
Use wiring that has been installed on the SYSTEM OF MOTOR CONTROL BOARD by Forward
Reverse control circuit for Star Delta to test and look for damage
SELF-ASSESSMENT QUESTIONS
1 (a) Explain what is meant by the term lsquoback emfrsquo in a motor
(b) Outline the basic differences between series shunt and compound wound dc motors
2 (a) With the aid of diagrams explain how the speed of series shunt and compound-wound motors
may be controlled
(b) A 440V dc shunt-wound motor has a field resistance of 200R and an armature resistance of 06 R
When its speed is 20 rev d second the current drawn from the supply is 122A Calculate its back
emf at this speed If the speed were decreased to 19 revssecond the field flux remaining unchanged
calculate the new back emf and the new armature current
3 A load of 64 kW at 240 V is supplied from the terminals of a shunt-wound dc generator The field
resistance is 180 A Calculate the armature current
4 (a) Explain with the aid of a diagram how a rotating magnetic field may be
(b) What is meant by lsquosynchronous speedrsquo
Calculate the synchronous obtained speed of a 12 pole motor if the supply frequency is 50Hz
5 (a) Explain the action of a synchronous motor
(b) What methods are available to start a synchronous motor Explain with diagrams
6 (a) Explain the action of a cage induction motor
(b) What is meant by the term lsquosliprsquo
Calculate the percentage slip of a six pole induction motor running at 162 revssecond from a 50 Hz
supply
7 Describe with sketches three different ways of starting a single-phase induction motor
12 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
8 Explain with the aid of a sketch the action of a three-phase DOL starter
What are dashpots used for How are remote start and stop buttons connected
9 A I0 kW 240V 50Hz single-phase cage rotor induction motor is 85efficient and has a PF of 068
lagging Calculate the motor current and the value of capacitor required to raise the PF to 093
lagging
10 Calculate the torque developed by an 18 kW four-pole induction motor run at 35 slip from a
50Hz supply
APPENDIX 1
13 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 11
14 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 111
Attachment Reference
httpswwwtlc-directcoukBook621htm
httpwwwstgovmyindexphpms
15 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
THREE PHASE DAHLANDER TYPE INDUCTION MOTOR OPERATED FORWARD AND
REVERSE OPERATION BY DIRECT ON LINE STARTER
84 ndash 99EASYTECH ENTERPRISE
LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
Introduction
If a motors windings are connected in the star configuration any two phases will be in series across
the supply and hence the line current will be smaller(by 577) than if the windings were connected in
the delta arrangement
Hence larger-type motors with heavy starting currents are first connected in star and then when the
starting currents fall in delta This of course means that all six of the ends of the windings must be
brought to terminations outside the casing (Fig 833)
EZTECH
EZTECH ELECTRICAL INSTALLATION GUIDE
The automatic version of this starter incorporates a timing relay which automatically changes the
connections from star to delta Figs 834 and 835 show the wiring and schematic diagrams for a star
delta starter
Objectives
1 Identify component and the specification
2 Design forward reverse star delta starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
2 ndash 99EASYTECH ENTERPRISE
REV -C
LEGENDMCCB Moulded Case Circuit BreakerTOR Thermal Over Load RelayFOW-C Mains Forward ContactorREV-C Mains Reverse ContactorDC Delta ContactorSC Star ContactorS-SW Mains Selector Switch
SC
V2
W2
U2
DC
V1
W1
U1
TOR
TOR
FOW-C
30A MCCB
TOR
MAIN CIRCUIT FORWARD REVERSE STAR DELTA
RYBN S
-SW
3 PHASEINDUCTION MOTOR
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Relay 10 A 240V 3
5 Triple pole Contactor
6 cw NO NC auxiliary contact
240Vac 20 A 4
7 Overload Relay 415 V 1
8 LED indicator 240vac 5 A 4
9 Start stop button 240Vac 5A 2
10 DIN rail 35 mm As required
11 Flexible wires 1 mm As required
12 Single core PVC insulated
wire
25 mm As required
13 Terminal block 20 A As required
14 Squirrel cage motor 5kW 1
15 5 pin plug and socket 415V 20A 1
16 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
3 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
a Manual star delta
b Manual Forward reverse star delta starter
c Automatic star delta starter
d Automatic Forward reverse star delta starter
4 Test the functionality of completed project
4 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
Objectives
1 Identify component and the specification
2 Design auto transformer starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
5 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Autotransformer starter is used to start a 3 phase induction motor that has a rating between 10 to 15 hp
6 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Autotransformer set 10Kw 415 V 50 Hz 1
5 Triple pole Contactor 240Vac 4
6 Batten type Lamp holder 240 Vac 105 A 4
7 Start stop button 240Vac 10A 4
8 Filament lamp (Bulb ) 240Vac 40W 4
9 DIN rail 35 mm As required
10 Flexible wires 1 mm As required
7 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
11 Single core PVC insulated
wire
25 mm As required
12 Terminal block 20 A As required
13 Squirrel cage motor 10kW 1
14 5 pin plug and socket 415V 20A 1
15 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a open transient autotransformer starter
b close transient autotransformer starter
c Forward reverse autotransformer starter
4 Test the functionality of completed project
8 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
Objectives
1 Identify component and the specification
2 Design rotor resistance starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
9 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Rotor Resistor set 10kW 1
5 Triple pole Contactor 240Vac 20A 4
6 Indicating light 240vac 5 A 4
7 Start stop push button 240Vac 5A 4
8 DIN rail 35 mm As required
9 Flexible wires 1 mm 2 As required
10 Single core PVC insulated wire 25 mm 2 As required
11 Terminal block 20 A As required
12 Slip Ring motor 10kW 1
13 5 pin round 3 phase socket 415V 20A 1
14 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
10 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
4 Test the functionality of completed project
a Dead circuit test b Life circuit test
5 Measure starting and running Amps
LESSON 16
TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
An installation in general will suffer damage
Damage usually occurs on the electric motor control as follows
1 Damage to the main circuit
2 Damage to the control circuit
The cause of the damage
i Overcurrent overload short circuit
ii Leakage current to ground
iii Equipment malfunction
iv The main control circuit
a Trip of main circuit protection devices fire
b Defect of motor terminal such as short circuit fire loose
v The control circuit is not functioning -
a contactor relay relay time overload relay does not work damaged burned
b Loose cable connection disconnected
Detecting and Repairing Damage
Examples of damage are as follows
i Motor does not work
ii Motor function and overload relay trips
iii Motor function but only partially functional control circuit
Methods of detecting damage
Among the known methods necessary to detect damage are as follows
1 Turn off the electricity at the main switch (main switch) in order to avoid any danger during the
work carried out to detect damage
2 Check all the protective gear that controls the motor control main circuit
11 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
3 Make sure the damage function control circuit
4 Check the control circuit according to the schematic circuit diagram of the motor control
5 Check the operation of the control circuit
Note
Use wiring that has been installed on the SYSTEM OF MOTOR CONTROL BOARD by Forward
Reverse control circuit for Star Delta to test and look for damage
SELF-ASSESSMENT QUESTIONS
1 (a) Explain what is meant by the term lsquoback emfrsquo in a motor
(b) Outline the basic differences between series shunt and compound wound dc motors
2 (a) With the aid of diagrams explain how the speed of series shunt and compound-wound motors
may be controlled
(b) A 440V dc shunt-wound motor has a field resistance of 200R and an armature resistance of 06 R
When its speed is 20 rev d second the current drawn from the supply is 122A Calculate its back
emf at this speed If the speed were decreased to 19 revssecond the field flux remaining unchanged
calculate the new back emf and the new armature current
3 A load of 64 kW at 240 V is supplied from the terminals of a shunt-wound dc generator The field
resistance is 180 A Calculate the armature current
4 (a) Explain with the aid of a diagram how a rotating magnetic field may be
(b) What is meant by lsquosynchronous speedrsquo
Calculate the synchronous obtained speed of a 12 pole motor if the supply frequency is 50Hz
5 (a) Explain the action of a synchronous motor
(b) What methods are available to start a synchronous motor Explain with diagrams
6 (a) Explain the action of a cage induction motor
(b) What is meant by the term lsquosliprsquo
Calculate the percentage slip of a six pole induction motor running at 162 revssecond from a 50 Hz
supply
7 Describe with sketches three different ways of starting a single-phase induction motor
12 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
8 Explain with the aid of a sketch the action of a three-phase DOL starter
What are dashpots used for How are remote start and stop buttons connected
9 A I0 kW 240V 50Hz single-phase cage rotor induction motor is 85efficient and has a PF of 068
lagging Calculate the motor current and the value of capacitor required to raise the PF to 093
lagging
10 Calculate the torque developed by an 18 kW four-pole induction motor run at 35 slip from a
50Hz supply
APPENDIX 1
13 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 11
14 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 111
Attachment Reference
httpswwwtlc-directcoukBook621htm
httpwwwstgovmyindexphpms
15 ndash 99EASYTECH ENTERPRISE
LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
Introduction
If a motors windings are connected in the star configuration any two phases will be in series across
the supply and hence the line current will be smaller(by 577) than if the windings were connected in
the delta arrangement
Hence larger-type motors with heavy starting currents are first connected in star and then when the
starting currents fall in delta This of course means that all six of the ends of the windings must be
brought to terminations outside the casing (Fig 833)
EZTECH
EZTECH ELECTRICAL INSTALLATION GUIDE
The automatic version of this starter incorporates a timing relay which automatically changes the
connections from star to delta Figs 834 and 835 show the wiring and schematic diagrams for a star
delta starter
Objectives
1 Identify component and the specification
2 Design forward reverse star delta starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
2 ndash 99EASYTECH ENTERPRISE
REV -C
LEGENDMCCB Moulded Case Circuit BreakerTOR Thermal Over Load RelayFOW-C Mains Forward ContactorREV-C Mains Reverse ContactorDC Delta ContactorSC Star ContactorS-SW Mains Selector Switch
SC
V2
W2
U2
DC
V1
W1
U1
TOR
TOR
FOW-C
30A MCCB
TOR
MAIN CIRCUIT FORWARD REVERSE STAR DELTA
RYBN S
-SW
3 PHASEINDUCTION MOTOR
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Relay 10 A 240V 3
5 Triple pole Contactor
6 cw NO NC auxiliary contact
240Vac 20 A 4
7 Overload Relay 415 V 1
8 LED indicator 240vac 5 A 4
9 Start stop button 240Vac 5A 2
10 DIN rail 35 mm As required
11 Flexible wires 1 mm As required
12 Single core PVC insulated
wire
25 mm As required
13 Terminal block 20 A As required
14 Squirrel cage motor 5kW 1
15 5 pin plug and socket 415V 20A 1
16 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
3 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
a Manual star delta
b Manual Forward reverse star delta starter
c Automatic star delta starter
d Automatic Forward reverse star delta starter
4 Test the functionality of completed project
4 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
Objectives
1 Identify component and the specification
2 Design auto transformer starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
5 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Autotransformer starter is used to start a 3 phase induction motor that has a rating between 10 to 15 hp
6 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Autotransformer set 10Kw 415 V 50 Hz 1
5 Triple pole Contactor 240Vac 4
6 Batten type Lamp holder 240 Vac 105 A 4
7 Start stop button 240Vac 10A 4
8 Filament lamp (Bulb ) 240Vac 40W 4
9 DIN rail 35 mm As required
10 Flexible wires 1 mm As required
7 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
11 Single core PVC insulated
wire
25 mm As required
12 Terminal block 20 A As required
13 Squirrel cage motor 10kW 1
14 5 pin plug and socket 415V 20A 1
15 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a open transient autotransformer starter
b close transient autotransformer starter
c Forward reverse autotransformer starter
4 Test the functionality of completed project
8 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
Objectives
1 Identify component and the specification
2 Design rotor resistance starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
9 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Rotor Resistor set 10kW 1
5 Triple pole Contactor 240Vac 20A 4
6 Indicating light 240vac 5 A 4
7 Start stop push button 240Vac 5A 4
8 DIN rail 35 mm As required
9 Flexible wires 1 mm 2 As required
10 Single core PVC insulated wire 25 mm 2 As required
11 Terminal block 20 A As required
12 Slip Ring motor 10kW 1
13 5 pin round 3 phase socket 415V 20A 1
14 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
10 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
4 Test the functionality of completed project
a Dead circuit test b Life circuit test
5 Measure starting and running Amps
LESSON 16
TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
An installation in general will suffer damage
Damage usually occurs on the electric motor control as follows
1 Damage to the main circuit
2 Damage to the control circuit
The cause of the damage
i Overcurrent overload short circuit
ii Leakage current to ground
iii Equipment malfunction
iv The main control circuit
a Trip of main circuit protection devices fire
b Defect of motor terminal such as short circuit fire loose
v The control circuit is not functioning -
a contactor relay relay time overload relay does not work damaged burned
b Loose cable connection disconnected
Detecting and Repairing Damage
Examples of damage are as follows
i Motor does not work
ii Motor function and overload relay trips
iii Motor function but only partially functional control circuit
Methods of detecting damage
Among the known methods necessary to detect damage are as follows
1 Turn off the electricity at the main switch (main switch) in order to avoid any danger during the
work carried out to detect damage
2 Check all the protective gear that controls the motor control main circuit
11 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
3 Make sure the damage function control circuit
4 Check the control circuit according to the schematic circuit diagram of the motor control
5 Check the operation of the control circuit
Note
Use wiring that has been installed on the SYSTEM OF MOTOR CONTROL BOARD by Forward
Reverse control circuit for Star Delta to test and look for damage
SELF-ASSESSMENT QUESTIONS
1 (a) Explain what is meant by the term lsquoback emfrsquo in a motor
(b) Outline the basic differences between series shunt and compound wound dc motors
2 (a) With the aid of diagrams explain how the speed of series shunt and compound-wound motors
may be controlled
(b) A 440V dc shunt-wound motor has a field resistance of 200R and an armature resistance of 06 R
When its speed is 20 rev d second the current drawn from the supply is 122A Calculate its back
emf at this speed If the speed were decreased to 19 revssecond the field flux remaining unchanged
calculate the new back emf and the new armature current
3 A load of 64 kW at 240 V is supplied from the terminals of a shunt-wound dc generator The field
resistance is 180 A Calculate the armature current
4 (a) Explain with the aid of a diagram how a rotating magnetic field may be
(b) What is meant by lsquosynchronous speedrsquo
Calculate the synchronous obtained speed of a 12 pole motor if the supply frequency is 50Hz
5 (a) Explain the action of a synchronous motor
(b) What methods are available to start a synchronous motor Explain with diagrams
6 (a) Explain the action of a cage induction motor
(b) What is meant by the term lsquosliprsquo
Calculate the percentage slip of a six pole induction motor running at 162 revssecond from a 50 Hz
supply
7 Describe with sketches three different ways of starting a single-phase induction motor
12 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
8 Explain with the aid of a sketch the action of a three-phase DOL starter
What are dashpots used for How are remote start and stop buttons connected
9 A I0 kW 240V 50Hz single-phase cage rotor induction motor is 85efficient and has a PF of 068
lagging Calculate the motor current and the value of capacitor required to raise the PF to 093
lagging
10 Calculate the torque developed by an 18 kW four-pole induction motor run at 35 slip from a
50Hz supply
APPENDIX 1
13 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 11
14 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 111
Attachment Reference
httpswwwtlc-directcoukBook621htm
httpwwwstgovmyindexphpms
15 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
The automatic version of this starter incorporates a timing relay which automatically changes the
connections from star to delta Figs 834 and 835 show the wiring and schematic diagrams for a star
delta starter
Objectives
1 Identify component and the specification
2 Design forward reverse star delta starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
2 ndash 99EASYTECH ENTERPRISE
REV -C
LEGENDMCCB Moulded Case Circuit BreakerTOR Thermal Over Load RelayFOW-C Mains Forward ContactorREV-C Mains Reverse ContactorDC Delta ContactorSC Star ContactorS-SW Mains Selector Switch
SC
V2
W2
U2
DC
V1
W1
U1
TOR
TOR
FOW-C
30A MCCB
TOR
MAIN CIRCUIT FORWARD REVERSE STAR DELTA
RYBN S
-SW
3 PHASEINDUCTION MOTOR
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Relay 10 A 240V 3
5 Triple pole Contactor
6 cw NO NC auxiliary contact
240Vac 20 A 4
7 Overload Relay 415 V 1
8 LED indicator 240vac 5 A 4
9 Start stop button 240Vac 5A 2
10 DIN rail 35 mm As required
11 Flexible wires 1 mm As required
12 Single core PVC insulated
wire
25 mm As required
13 Terminal block 20 A As required
14 Squirrel cage motor 5kW 1
15 5 pin plug and socket 415V 20A 1
16 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
3 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
a Manual star delta
b Manual Forward reverse star delta starter
c Automatic star delta starter
d Automatic Forward reverse star delta starter
4 Test the functionality of completed project
4 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
Objectives
1 Identify component and the specification
2 Design auto transformer starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
5 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Autotransformer starter is used to start a 3 phase induction motor that has a rating between 10 to 15 hp
6 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Autotransformer set 10Kw 415 V 50 Hz 1
5 Triple pole Contactor 240Vac 4
6 Batten type Lamp holder 240 Vac 105 A 4
7 Start stop button 240Vac 10A 4
8 Filament lamp (Bulb ) 240Vac 40W 4
9 DIN rail 35 mm As required
10 Flexible wires 1 mm As required
7 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
11 Single core PVC insulated
wire
25 mm As required
12 Terminal block 20 A As required
13 Squirrel cage motor 10kW 1
14 5 pin plug and socket 415V 20A 1
15 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a open transient autotransformer starter
b close transient autotransformer starter
c Forward reverse autotransformer starter
4 Test the functionality of completed project
8 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
Objectives
1 Identify component and the specification
2 Design rotor resistance starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
9 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Rotor Resistor set 10kW 1
5 Triple pole Contactor 240Vac 20A 4
6 Indicating light 240vac 5 A 4
7 Start stop push button 240Vac 5A 4
8 DIN rail 35 mm As required
9 Flexible wires 1 mm 2 As required
10 Single core PVC insulated wire 25 mm 2 As required
11 Terminal block 20 A As required
12 Slip Ring motor 10kW 1
13 5 pin round 3 phase socket 415V 20A 1
14 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
10 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
4 Test the functionality of completed project
a Dead circuit test b Life circuit test
5 Measure starting and running Amps
LESSON 16
TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
An installation in general will suffer damage
Damage usually occurs on the electric motor control as follows
1 Damage to the main circuit
2 Damage to the control circuit
The cause of the damage
i Overcurrent overload short circuit
ii Leakage current to ground
iii Equipment malfunction
iv The main control circuit
a Trip of main circuit protection devices fire
b Defect of motor terminal such as short circuit fire loose
v The control circuit is not functioning -
a contactor relay relay time overload relay does not work damaged burned
b Loose cable connection disconnected
Detecting and Repairing Damage
Examples of damage are as follows
i Motor does not work
ii Motor function and overload relay trips
iii Motor function but only partially functional control circuit
Methods of detecting damage
Among the known methods necessary to detect damage are as follows
1 Turn off the electricity at the main switch (main switch) in order to avoid any danger during the
work carried out to detect damage
2 Check all the protective gear that controls the motor control main circuit
11 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
3 Make sure the damage function control circuit
4 Check the control circuit according to the schematic circuit diagram of the motor control
5 Check the operation of the control circuit
Note
Use wiring that has been installed on the SYSTEM OF MOTOR CONTROL BOARD by Forward
Reverse control circuit for Star Delta to test and look for damage
SELF-ASSESSMENT QUESTIONS
1 (a) Explain what is meant by the term lsquoback emfrsquo in a motor
(b) Outline the basic differences between series shunt and compound wound dc motors
2 (a) With the aid of diagrams explain how the speed of series shunt and compound-wound motors
may be controlled
(b) A 440V dc shunt-wound motor has a field resistance of 200R and an armature resistance of 06 R
When its speed is 20 rev d second the current drawn from the supply is 122A Calculate its back
emf at this speed If the speed were decreased to 19 revssecond the field flux remaining unchanged
calculate the new back emf and the new armature current
3 A load of 64 kW at 240 V is supplied from the terminals of a shunt-wound dc generator The field
resistance is 180 A Calculate the armature current
4 (a) Explain with the aid of a diagram how a rotating magnetic field may be
(b) What is meant by lsquosynchronous speedrsquo
Calculate the synchronous obtained speed of a 12 pole motor if the supply frequency is 50Hz
5 (a) Explain the action of a synchronous motor
(b) What methods are available to start a synchronous motor Explain with diagrams
6 (a) Explain the action of a cage induction motor
(b) What is meant by the term lsquosliprsquo
Calculate the percentage slip of a six pole induction motor running at 162 revssecond from a 50 Hz
supply
7 Describe with sketches three different ways of starting a single-phase induction motor
12 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
8 Explain with the aid of a sketch the action of a three-phase DOL starter
What are dashpots used for How are remote start and stop buttons connected
9 A I0 kW 240V 50Hz single-phase cage rotor induction motor is 85efficient and has a PF of 068
lagging Calculate the motor current and the value of capacitor required to raise the PF to 093
lagging
10 Calculate the torque developed by an 18 kW four-pole induction motor run at 35 slip from a
50Hz supply
APPENDIX 1
13 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 11
14 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 111
Attachment Reference
httpswwwtlc-directcoukBook621htm
httpwwwstgovmyindexphpms
15 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Relay 10 A 240V 3
5 Triple pole Contactor
6 cw NO NC auxiliary contact
240Vac 20 A 4
7 Overload Relay 415 V 1
8 LED indicator 240vac 5 A 4
9 Start stop button 240Vac 5A 2
10 DIN rail 35 mm As required
11 Flexible wires 1 mm As required
12 Single core PVC insulated
wire
25 mm As required
13 Terminal block 20 A As required
14 Squirrel cage motor 5kW 1
15 5 pin plug and socket 415V 20A 1
16 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
3 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
a Manual star delta
b Manual Forward reverse star delta starter
c Automatic star delta starter
d Automatic Forward reverse star delta starter
4 Test the functionality of completed project
4 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
Objectives
1 Identify component and the specification
2 Design auto transformer starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
5 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Autotransformer starter is used to start a 3 phase induction motor that has a rating between 10 to 15 hp
6 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Autotransformer set 10Kw 415 V 50 Hz 1
5 Triple pole Contactor 240Vac 4
6 Batten type Lamp holder 240 Vac 105 A 4
7 Start stop button 240Vac 10A 4
8 Filament lamp (Bulb ) 240Vac 40W 4
9 DIN rail 35 mm As required
10 Flexible wires 1 mm As required
7 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
11 Single core PVC insulated
wire
25 mm As required
12 Terminal block 20 A As required
13 Squirrel cage motor 10kW 1
14 5 pin plug and socket 415V 20A 1
15 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a open transient autotransformer starter
b close transient autotransformer starter
c Forward reverse autotransformer starter
4 Test the functionality of completed project
8 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
Objectives
1 Identify component and the specification
2 Design rotor resistance starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
9 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Rotor Resistor set 10kW 1
5 Triple pole Contactor 240Vac 20A 4
6 Indicating light 240vac 5 A 4
7 Start stop push button 240Vac 5A 4
8 DIN rail 35 mm As required
9 Flexible wires 1 mm 2 As required
10 Single core PVC insulated wire 25 mm 2 As required
11 Terminal block 20 A As required
12 Slip Ring motor 10kW 1
13 5 pin round 3 phase socket 415V 20A 1
14 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
10 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
4 Test the functionality of completed project
a Dead circuit test b Life circuit test
5 Measure starting and running Amps
LESSON 16
TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
An installation in general will suffer damage
Damage usually occurs on the electric motor control as follows
1 Damage to the main circuit
2 Damage to the control circuit
The cause of the damage
i Overcurrent overload short circuit
ii Leakage current to ground
iii Equipment malfunction
iv The main control circuit
a Trip of main circuit protection devices fire
b Defect of motor terminal such as short circuit fire loose
v The control circuit is not functioning -
a contactor relay relay time overload relay does not work damaged burned
b Loose cable connection disconnected
Detecting and Repairing Damage
Examples of damage are as follows
i Motor does not work
ii Motor function and overload relay trips
iii Motor function but only partially functional control circuit
Methods of detecting damage
Among the known methods necessary to detect damage are as follows
1 Turn off the electricity at the main switch (main switch) in order to avoid any danger during the
work carried out to detect damage
2 Check all the protective gear that controls the motor control main circuit
11 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
3 Make sure the damage function control circuit
4 Check the control circuit according to the schematic circuit diagram of the motor control
5 Check the operation of the control circuit
Note
Use wiring that has been installed on the SYSTEM OF MOTOR CONTROL BOARD by Forward
Reverse control circuit for Star Delta to test and look for damage
SELF-ASSESSMENT QUESTIONS
1 (a) Explain what is meant by the term lsquoback emfrsquo in a motor
(b) Outline the basic differences between series shunt and compound wound dc motors
2 (a) With the aid of diagrams explain how the speed of series shunt and compound-wound motors
may be controlled
(b) A 440V dc shunt-wound motor has a field resistance of 200R and an armature resistance of 06 R
When its speed is 20 rev d second the current drawn from the supply is 122A Calculate its back
emf at this speed If the speed were decreased to 19 revssecond the field flux remaining unchanged
calculate the new back emf and the new armature current
3 A load of 64 kW at 240 V is supplied from the terminals of a shunt-wound dc generator The field
resistance is 180 A Calculate the armature current
4 (a) Explain with the aid of a diagram how a rotating magnetic field may be
(b) What is meant by lsquosynchronous speedrsquo
Calculate the synchronous obtained speed of a 12 pole motor if the supply frequency is 50Hz
5 (a) Explain the action of a synchronous motor
(b) What methods are available to start a synchronous motor Explain with diagrams
6 (a) Explain the action of a cage induction motor
(b) What is meant by the term lsquosliprsquo
Calculate the percentage slip of a six pole induction motor running at 162 revssecond from a 50 Hz
supply
7 Describe with sketches three different ways of starting a single-phase induction motor
12 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
8 Explain with the aid of a sketch the action of a three-phase DOL starter
What are dashpots used for How are remote start and stop buttons connected
9 A I0 kW 240V 50Hz single-phase cage rotor induction motor is 85efficient and has a PF of 068
lagging Calculate the motor current and the value of capacitor required to raise the PF to 093
lagging
10 Calculate the torque developed by an 18 kW four-pole induction motor run at 35 slip from a
50Hz supply
APPENDIX 1
13 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 11
14 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 111
Attachment Reference
httpswwwtlc-directcoukBook621htm
httpwwwstgovmyindexphpms
15 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
2 Test the functionality of each component by using multimeter or power supply whichever
applicable
3 Wire component according to circuit diagram
a Manual star delta
b Manual Forward reverse star delta starter
c Automatic star delta starter
d Automatic Forward reverse star delta starter
4 Test the functionality of completed project
4 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
Objectives
1 Identify component and the specification
2 Design auto transformer starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
5 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Autotransformer starter is used to start a 3 phase induction motor that has a rating between 10 to 15 hp
6 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Autotransformer set 10Kw 415 V 50 Hz 1
5 Triple pole Contactor 240Vac 4
6 Batten type Lamp holder 240 Vac 105 A 4
7 Start stop button 240Vac 10A 4
8 Filament lamp (Bulb ) 240Vac 40W 4
9 DIN rail 35 mm As required
10 Flexible wires 1 mm As required
7 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
11 Single core PVC insulated
wire
25 mm As required
12 Terminal block 20 A As required
13 Squirrel cage motor 10kW 1
14 5 pin plug and socket 415V 20A 1
15 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a open transient autotransformer starter
b close transient autotransformer starter
c Forward reverse autotransformer starter
4 Test the functionality of completed project
8 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
Objectives
1 Identify component and the specification
2 Design rotor resistance starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
9 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Rotor Resistor set 10kW 1
5 Triple pole Contactor 240Vac 20A 4
6 Indicating light 240vac 5 A 4
7 Start stop push button 240Vac 5A 4
8 DIN rail 35 mm As required
9 Flexible wires 1 mm 2 As required
10 Single core PVC insulated wire 25 mm 2 As required
11 Terminal block 20 A As required
12 Slip Ring motor 10kW 1
13 5 pin round 3 phase socket 415V 20A 1
14 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
10 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
4 Test the functionality of completed project
a Dead circuit test b Life circuit test
5 Measure starting and running Amps
LESSON 16
TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
An installation in general will suffer damage
Damage usually occurs on the electric motor control as follows
1 Damage to the main circuit
2 Damage to the control circuit
The cause of the damage
i Overcurrent overload short circuit
ii Leakage current to ground
iii Equipment malfunction
iv The main control circuit
a Trip of main circuit protection devices fire
b Defect of motor terminal such as short circuit fire loose
v The control circuit is not functioning -
a contactor relay relay time overload relay does not work damaged burned
b Loose cable connection disconnected
Detecting and Repairing Damage
Examples of damage are as follows
i Motor does not work
ii Motor function and overload relay trips
iii Motor function but only partially functional control circuit
Methods of detecting damage
Among the known methods necessary to detect damage are as follows
1 Turn off the electricity at the main switch (main switch) in order to avoid any danger during the
work carried out to detect damage
2 Check all the protective gear that controls the motor control main circuit
11 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
3 Make sure the damage function control circuit
4 Check the control circuit according to the schematic circuit diagram of the motor control
5 Check the operation of the control circuit
Note
Use wiring that has been installed on the SYSTEM OF MOTOR CONTROL BOARD by Forward
Reverse control circuit for Star Delta to test and look for damage
SELF-ASSESSMENT QUESTIONS
1 (a) Explain what is meant by the term lsquoback emfrsquo in a motor
(b) Outline the basic differences between series shunt and compound wound dc motors
2 (a) With the aid of diagrams explain how the speed of series shunt and compound-wound motors
may be controlled
(b) A 440V dc shunt-wound motor has a field resistance of 200R and an armature resistance of 06 R
When its speed is 20 rev d second the current drawn from the supply is 122A Calculate its back
emf at this speed If the speed were decreased to 19 revssecond the field flux remaining unchanged
calculate the new back emf and the new armature current
3 A load of 64 kW at 240 V is supplied from the terminals of a shunt-wound dc generator The field
resistance is 180 A Calculate the armature current
4 (a) Explain with the aid of a diagram how a rotating magnetic field may be
(b) What is meant by lsquosynchronous speedrsquo
Calculate the synchronous obtained speed of a 12 pole motor if the supply frequency is 50Hz
5 (a) Explain the action of a synchronous motor
(b) What methods are available to start a synchronous motor Explain with diagrams
6 (a) Explain the action of a cage induction motor
(b) What is meant by the term lsquosliprsquo
Calculate the percentage slip of a six pole induction motor running at 162 revssecond from a 50 Hz
supply
7 Describe with sketches three different ways of starting a single-phase induction motor
12 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
8 Explain with the aid of a sketch the action of a three-phase DOL starter
What are dashpots used for How are remote start and stop buttons connected
9 A I0 kW 240V 50Hz single-phase cage rotor induction motor is 85efficient and has a PF of 068
lagging Calculate the motor current and the value of capacitor required to raise the PF to 093
lagging
10 Calculate the torque developed by an 18 kW four-pole induction motor run at 35 slip from a
50Hz supply
APPENDIX 1
13 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 11
14 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 111
Attachment Reference
httpswwwtlc-directcoukBook621htm
httpwwwstgovmyindexphpms
15 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
Objectives
1 Identify component and the specification
2 Design auto transformer starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
5 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Autotransformer starter is used to start a 3 phase induction motor that has a rating between 10 to 15 hp
6 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Autotransformer set 10Kw 415 V 50 Hz 1
5 Triple pole Contactor 240Vac 4
6 Batten type Lamp holder 240 Vac 105 A 4
7 Start stop button 240Vac 10A 4
8 Filament lamp (Bulb ) 240Vac 40W 4
9 DIN rail 35 mm As required
10 Flexible wires 1 mm As required
7 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
11 Single core PVC insulated
wire
25 mm As required
12 Terminal block 20 A As required
13 Squirrel cage motor 10kW 1
14 5 pin plug and socket 415V 20A 1
15 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a open transient autotransformer starter
b close transient autotransformer starter
c Forward reverse autotransformer starter
4 Test the functionality of completed project
8 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
Objectives
1 Identify component and the specification
2 Design rotor resistance starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
9 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Rotor Resistor set 10kW 1
5 Triple pole Contactor 240Vac 20A 4
6 Indicating light 240vac 5 A 4
7 Start stop push button 240Vac 5A 4
8 DIN rail 35 mm As required
9 Flexible wires 1 mm 2 As required
10 Single core PVC insulated wire 25 mm 2 As required
11 Terminal block 20 A As required
12 Slip Ring motor 10kW 1
13 5 pin round 3 phase socket 415V 20A 1
14 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
10 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
4 Test the functionality of completed project
a Dead circuit test b Life circuit test
5 Measure starting and running Amps
LESSON 16
TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
An installation in general will suffer damage
Damage usually occurs on the electric motor control as follows
1 Damage to the main circuit
2 Damage to the control circuit
The cause of the damage
i Overcurrent overload short circuit
ii Leakage current to ground
iii Equipment malfunction
iv The main control circuit
a Trip of main circuit protection devices fire
b Defect of motor terminal such as short circuit fire loose
v The control circuit is not functioning -
a contactor relay relay time overload relay does not work damaged burned
b Loose cable connection disconnected
Detecting and Repairing Damage
Examples of damage are as follows
i Motor does not work
ii Motor function and overload relay trips
iii Motor function but only partially functional control circuit
Methods of detecting damage
Among the known methods necessary to detect damage are as follows
1 Turn off the electricity at the main switch (main switch) in order to avoid any danger during the
work carried out to detect damage
2 Check all the protective gear that controls the motor control main circuit
11 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
3 Make sure the damage function control circuit
4 Check the control circuit according to the schematic circuit diagram of the motor control
5 Check the operation of the control circuit
Note
Use wiring that has been installed on the SYSTEM OF MOTOR CONTROL BOARD by Forward
Reverse control circuit for Star Delta to test and look for damage
SELF-ASSESSMENT QUESTIONS
1 (a) Explain what is meant by the term lsquoback emfrsquo in a motor
(b) Outline the basic differences between series shunt and compound wound dc motors
2 (a) With the aid of diagrams explain how the speed of series shunt and compound-wound motors
may be controlled
(b) A 440V dc shunt-wound motor has a field resistance of 200R and an armature resistance of 06 R
When its speed is 20 rev d second the current drawn from the supply is 122A Calculate its back
emf at this speed If the speed were decreased to 19 revssecond the field flux remaining unchanged
calculate the new back emf and the new armature current
3 A load of 64 kW at 240 V is supplied from the terminals of a shunt-wound dc generator The field
resistance is 180 A Calculate the armature current
4 (a) Explain with the aid of a diagram how a rotating magnetic field may be
(b) What is meant by lsquosynchronous speedrsquo
Calculate the synchronous obtained speed of a 12 pole motor if the supply frequency is 50Hz
5 (a) Explain the action of a synchronous motor
(b) What methods are available to start a synchronous motor Explain with diagrams
6 (a) Explain the action of a cage induction motor
(b) What is meant by the term lsquosliprsquo
Calculate the percentage slip of a six pole induction motor running at 162 revssecond from a 50 Hz
supply
7 Describe with sketches three different ways of starting a single-phase induction motor
12 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
8 Explain with the aid of a sketch the action of a three-phase DOL starter
What are dashpots used for How are remote start and stop buttons connected
9 A I0 kW 240V 50Hz single-phase cage rotor induction motor is 85efficient and has a PF of 068
lagging Calculate the motor current and the value of capacitor required to raise the PF to 093
lagging
10 Calculate the torque developed by an 18 kW four-pole induction motor run at 35 slip from a
50Hz supply
APPENDIX 1
13 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 11
14 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 111
Attachment Reference
httpswwwtlc-directcoukBook621htm
httpwwwstgovmyindexphpms
15 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
Autotransformer starter is used to start a 3 phase induction motor that has a rating between 10 to 15 hp
6 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Autotransformer set 10Kw 415 V 50 Hz 1
5 Triple pole Contactor 240Vac 4
6 Batten type Lamp holder 240 Vac 105 A 4
7 Start stop button 240Vac 10A 4
8 Filament lamp (Bulb ) 240Vac 40W 4
9 DIN rail 35 mm As required
10 Flexible wires 1 mm As required
7 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
11 Single core PVC insulated
wire
25 mm As required
12 Terminal block 20 A As required
13 Squirrel cage motor 10kW 1
14 5 pin plug and socket 415V 20A 1
15 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a open transient autotransformer starter
b close transient autotransformer starter
c Forward reverse autotransformer starter
4 Test the functionality of completed project
8 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
Objectives
1 Identify component and the specification
2 Design rotor resistance starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
9 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Rotor Resistor set 10kW 1
5 Triple pole Contactor 240Vac 20A 4
6 Indicating light 240vac 5 A 4
7 Start stop push button 240Vac 5A 4
8 DIN rail 35 mm As required
9 Flexible wires 1 mm 2 As required
10 Single core PVC insulated wire 25 mm 2 As required
11 Terminal block 20 A As required
12 Slip Ring motor 10kW 1
13 5 pin round 3 phase socket 415V 20A 1
14 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
10 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
4 Test the functionality of completed project
a Dead circuit test b Life circuit test
5 Measure starting and running Amps
LESSON 16
TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
An installation in general will suffer damage
Damage usually occurs on the electric motor control as follows
1 Damage to the main circuit
2 Damage to the control circuit
The cause of the damage
i Overcurrent overload short circuit
ii Leakage current to ground
iii Equipment malfunction
iv The main control circuit
a Trip of main circuit protection devices fire
b Defect of motor terminal such as short circuit fire loose
v The control circuit is not functioning -
a contactor relay relay time overload relay does not work damaged burned
b Loose cable connection disconnected
Detecting and Repairing Damage
Examples of damage are as follows
i Motor does not work
ii Motor function and overload relay trips
iii Motor function but only partially functional control circuit
Methods of detecting damage
Among the known methods necessary to detect damage are as follows
1 Turn off the electricity at the main switch (main switch) in order to avoid any danger during the
work carried out to detect damage
2 Check all the protective gear that controls the motor control main circuit
11 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
3 Make sure the damage function control circuit
4 Check the control circuit according to the schematic circuit diagram of the motor control
5 Check the operation of the control circuit
Note
Use wiring that has been installed on the SYSTEM OF MOTOR CONTROL BOARD by Forward
Reverse control circuit for Star Delta to test and look for damage
SELF-ASSESSMENT QUESTIONS
1 (a) Explain what is meant by the term lsquoback emfrsquo in a motor
(b) Outline the basic differences between series shunt and compound wound dc motors
2 (a) With the aid of diagrams explain how the speed of series shunt and compound-wound motors
may be controlled
(b) A 440V dc shunt-wound motor has a field resistance of 200R and an armature resistance of 06 R
When its speed is 20 rev d second the current drawn from the supply is 122A Calculate its back
emf at this speed If the speed were decreased to 19 revssecond the field flux remaining unchanged
calculate the new back emf and the new armature current
3 A load of 64 kW at 240 V is supplied from the terminals of a shunt-wound dc generator The field
resistance is 180 A Calculate the armature current
4 (a) Explain with the aid of a diagram how a rotating magnetic field may be
(b) What is meant by lsquosynchronous speedrsquo
Calculate the synchronous obtained speed of a 12 pole motor if the supply frequency is 50Hz
5 (a) Explain the action of a synchronous motor
(b) What methods are available to start a synchronous motor Explain with diagrams
6 (a) Explain the action of a cage induction motor
(b) What is meant by the term lsquosliprsquo
Calculate the percentage slip of a six pole induction motor running at 162 revssecond from a 50 Hz
supply
7 Describe with sketches three different ways of starting a single-phase induction motor
12 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
8 Explain with the aid of a sketch the action of a three-phase DOL starter
What are dashpots used for How are remote start and stop buttons connected
9 A I0 kW 240V 50Hz single-phase cage rotor induction motor is 85efficient and has a PF of 068
lagging Calculate the motor current and the value of capacitor required to raise the PF to 093
lagging
10 Calculate the torque developed by an 18 kW four-pole induction motor run at 35 slip from a
50Hz supply
APPENDIX 1
13 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 11
14 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 111
Attachment Reference
httpswwwtlc-directcoukBook621htm
httpwwwstgovmyindexphpms
15 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Autotransformer set 10Kw 415 V 50 Hz 1
5 Triple pole Contactor 240Vac 4
6 Batten type Lamp holder 240 Vac 105 A 4
7 Start stop button 240Vac 10A 4
8 Filament lamp (Bulb ) 240Vac 40W 4
9 DIN rail 35 mm As required
10 Flexible wires 1 mm As required
7 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
11 Single core PVC insulated
wire
25 mm As required
12 Terminal block 20 A As required
13 Squirrel cage motor 10kW 1
14 5 pin plug and socket 415V 20A 1
15 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a open transient autotransformer starter
b close transient autotransformer starter
c Forward reverse autotransformer starter
4 Test the functionality of completed project
8 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
Objectives
1 Identify component and the specification
2 Design rotor resistance starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
9 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Rotor Resistor set 10kW 1
5 Triple pole Contactor 240Vac 20A 4
6 Indicating light 240vac 5 A 4
7 Start stop push button 240Vac 5A 4
8 DIN rail 35 mm As required
9 Flexible wires 1 mm 2 As required
10 Single core PVC insulated wire 25 mm 2 As required
11 Terminal block 20 A As required
12 Slip Ring motor 10kW 1
13 5 pin round 3 phase socket 415V 20A 1
14 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
10 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
4 Test the functionality of completed project
a Dead circuit test b Life circuit test
5 Measure starting and running Amps
LESSON 16
TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
An installation in general will suffer damage
Damage usually occurs on the electric motor control as follows
1 Damage to the main circuit
2 Damage to the control circuit
The cause of the damage
i Overcurrent overload short circuit
ii Leakage current to ground
iii Equipment malfunction
iv The main control circuit
a Trip of main circuit protection devices fire
b Defect of motor terminal such as short circuit fire loose
v The control circuit is not functioning -
a contactor relay relay time overload relay does not work damaged burned
b Loose cable connection disconnected
Detecting and Repairing Damage
Examples of damage are as follows
i Motor does not work
ii Motor function and overload relay trips
iii Motor function but only partially functional control circuit
Methods of detecting damage
Among the known methods necessary to detect damage are as follows
1 Turn off the electricity at the main switch (main switch) in order to avoid any danger during the
work carried out to detect damage
2 Check all the protective gear that controls the motor control main circuit
11 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
3 Make sure the damage function control circuit
4 Check the control circuit according to the schematic circuit diagram of the motor control
5 Check the operation of the control circuit
Note
Use wiring that has been installed on the SYSTEM OF MOTOR CONTROL BOARD by Forward
Reverse control circuit for Star Delta to test and look for damage
SELF-ASSESSMENT QUESTIONS
1 (a) Explain what is meant by the term lsquoback emfrsquo in a motor
(b) Outline the basic differences between series shunt and compound wound dc motors
2 (a) With the aid of diagrams explain how the speed of series shunt and compound-wound motors
may be controlled
(b) A 440V dc shunt-wound motor has a field resistance of 200R and an armature resistance of 06 R
When its speed is 20 rev d second the current drawn from the supply is 122A Calculate its back
emf at this speed If the speed were decreased to 19 revssecond the field flux remaining unchanged
calculate the new back emf and the new armature current
3 A load of 64 kW at 240 V is supplied from the terminals of a shunt-wound dc generator The field
resistance is 180 A Calculate the armature current
4 (a) Explain with the aid of a diagram how a rotating magnetic field may be
(b) What is meant by lsquosynchronous speedrsquo
Calculate the synchronous obtained speed of a 12 pole motor if the supply frequency is 50Hz
5 (a) Explain the action of a synchronous motor
(b) What methods are available to start a synchronous motor Explain with diagrams
6 (a) Explain the action of a cage induction motor
(b) What is meant by the term lsquosliprsquo
Calculate the percentage slip of a six pole induction motor running at 162 revssecond from a 50 Hz
supply
7 Describe with sketches three different ways of starting a single-phase induction motor
12 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
8 Explain with the aid of a sketch the action of a three-phase DOL starter
What are dashpots used for How are remote start and stop buttons connected
9 A I0 kW 240V 50Hz single-phase cage rotor induction motor is 85efficient and has a PF of 068
lagging Calculate the motor current and the value of capacitor required to raise the PF to 093
lagging
10 Calculate the torque developed by an 18 kW four-pole induction motor run at 35 slip from a
50Hz supply
APPENDIX 1
13 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 11
14 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 111
Attachment Reference
httpswwwtlc-directcoukBook621htm
httpwwwstgovmyindexphpms
15 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
11 Single core PVC insulated
wire
25 mm As required
12 Terminal block 20 A As required
13 Squirrel cage motor 10kW 1
14 5 pin plug and socket 415V 20A 1
15 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
a open transient autotransformer starter
b close transient autotransformer starter
c Forward reverse autotransformer starter
4 Test the functionality of completed project
8 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
Objectives
1 Identify component and the specification
2 Design rotor resistance starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
9 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Rotor Resistor set 10kW 1
5 Triple pole Contactor 240Vac 20A 4
6 Indicating light 240vac 5 A 4
7 Start stop push button 240Vac 5A 4
8 DIN rail 35 mm As required
9 Flexible wires 1 mm 2 As required
10 Single core PVC insulated wire 25 mm 2 As required
11 Terminal block 20 A As required
12 Slip Ring motor 10kW 1
13 5 pin round 3 phase socket 415V 20A 1
14 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
10 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
4 Test the functionality of completed project
a Dead circuit test b Life circuit test
5 Measure starting and running Amps
LESSON 16
TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
An installation in general will suffer damage
Damage usually occurs on the electric motor control as follows
1 Damage to the main circuit
2 Damage to the control circuit
The cause of the damage
i Overcurrent overload short circuit
ii Leakage current to ground
iii Equipment malfunction
iv The main control circuit
a Trip of main circuit protection devices fire
b Defect of motor terminal such as short circuit fire loose
v The control circuit is not functioning -
a contactor relay relay time overload relay does not work damaged burned
b Loose cable connection disconnected
Detecting and Repairing Damage
Examples of damage are as follows
i Motor does not work
ii Motor function and overload relay trips
iii Motor function but only partially functional control circuit
Methods of detecting damage
Among the known methods necessary to detect damage are as follows
1 Turn off the electricity at the main switch (main switch) in order to avoid any danger during the
work carried out to detect damage
2 Check all the protective gear that controls the motor control main circuit
11 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
3 Make sure the damage function control circuit
4 Check the control circuit according to the schematic circuit diagram of the motor control
5 Check the operation of the control circuit
Note
Use wiring that has been installed on the SYSTEM OF MOTOR CONTROL BOARD by Forward
Reverse control circuit for Star Delta to test and look for damage
SELF-ASSESSMENT QUESTIONS
1 (a) Explain what is meant by the term lsquoback emfrsquo in a motor
(b) Outline the basic differences between series shunt and compound wound dc motors
2 (a) With the aid of diagrams explain how the speed of series shunt and compound-wound motors
may be controlled
(b) A 440V dc shunt-wound motor has a field resistance of 200R and an armature resistance of 06 R
When its speed is 20 rev d second the current drawn from the supply is 122A Calculate its back
emf at this speed If the speed were decreased to 19 revssecond the field flux remaining unchanged
calculate the new back emf and the new armature current
3 A load of 64 kW at 240 V is supplied from the terminals of a shunt-wound dc generator The field
resistance is 180 A Calculate the armature current
4 (a) Explain with the aid of a diagram how a rotating magnetic field may be
(b) What is meant by lsquosynchronous speedrsquo
Calculate the synchronous obtained speed of a 12 pole motor if the supply frequency is 50Hz
5 (a) Explain the action of a synchronous motor
(b) What methods are available to start a synchronous motor Explain with diagrams
6 (a) Explain the action of a cage induction motor
(b) What is meant by the term lsquosliprsquo
Calculate the percentage slip of a six pole induction motor running at 162 revssecond from a 50 Hz
supply
7 Describe with sketches three different ways of starting a single-phase induction motor
12 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
8 Explain with the aid of a sketch the action of a three-phase DOL starter
What are dashpots used for How are remote start and stop buttons connected
9 A I0 kW 240V 50Hz single-phase cage rotor induction motor is 85efficient and has a PF of 068
lagging Calculate the motor current and the value of capacitor required to raise the PF to 093
lagging
10 Calculate the torque developed by an 18 kW four-pole induction motor run at 35 slip from a
50Hz supply
APPENDIX 1
13 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 11
14 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 111
Attachment Reference
httpswwwtlc-directcoukBook621htm
httpwwwstgovmyindexphpms
15 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
Objectives
1 Identify component and the specification
2 Design rotor resistance starter
3 Wire component according to the schematic diagram
4 Test the functionality of the circuit
9 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Rotor Resistor set 10kW 1
5 Triple pole Contactor 240Vac 20A 4
6 Indicating light 240vac 5 A 4
7 Start stop push button 240Vac 5A 4
8 DIN rail 35 mm As required
9 Flexible wires 1 mm 2 As required
10 Single core PVC insulated wire 25 mm 2 As required
11 Terminal block 20 A As required
12 Slip Ring motor 10kW 1
13 5 pin round 3 phase socket 415V 20A 1
14 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
10 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
4 Test the functionality of completed project
a Dead circuit test b Life circuit test
5 Measure starting and running Amps
LESSON 16
TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
An installation in general will suffer damage
Damage usually occurs on the electric motor control as follows
1 Damage to the main circuit
2 Damage to the control circuit
The cause of the damage
i Overcurrent overload short circuit
ii Leakage current to ground
iii Equipment malfunction
iv The main control circuit
a Trip of main circuit protection devices fire
b Defect of motor terminal such as short circuit fire loose
v The control circuit is not functioning -
a contactor relay relay time overload relay does not work damaged burned
b Loose cable connection disconnected
Detecting and Repairing Damage
Examples of damage are as follows
i Motor does not work
ii Motor function and overload relay trips
iii Motor function but only partially functional control circuit
Methods of detecting damage
Among the known methods necessary to detect damage are as follows
1 Turn off the electricity at the main switch (main switch) in order to avoid any danger during the
work carried out to detect damage
2 Check all the protective gear that controls the motor control main circuit
11 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
3 Make sure the damage function control circuit
4 Check the control circuit according to the schematic circuit diagram of the motor control
5 Check the operation of the control circuit
Note
Use wiring that has been installed on the SYSTEM OF MOTOR CONTROL BOARD by Forward
Reverse control circuit for Star Delta to test and look for damage
SELF-ASSESSMENT QUESTIONS
1 (a) Explain what is meant by the term lsquoback emfrsquo in a motor
(b) Outline the basic differences between series shunt and compound wound dc motors
2 (a) With the aid of diagrams explain how the speed of series shunt and compound-wound motors
may be controlled
(b) A 440V dc shunt-wound motor has a field resistance of 200R and an armature resistance of 06 R
When its speed is 20 rev d second the current drawn from the supply is 122A Calculate its back
emf at this speed If the speed were decreased to 19 revssecond the field flux remaining unchanged
calculate the new back emf and the new armature current
3 A load of 64 kW at 240 V is supplied from the terminals of a shunt-wound dc generator The field
resistance is 180 A Calculate the armature current
4 (a) Explain with the aid of a diagram how a rotating magnetic field may be
(b) What is meant by lsquosynchronous speedrsquo
Calculate the synchronous obtained speed of a 12 pole motor if the supply frequency is 50Hz
5 (a) Explain the action of a synchronous motor
(b) What methods are available to start a synchronous motor Explain with diagrams
6 (a) Explain the action of a cage induction motor
(b) What is meant by the term lsquosliprsquo
Calculate the percentage slip of a six pole induction motor running at 162 revssecond from a 50 Hz
supply
7 Describe with sketches three different ways of starting a single-phase induction motor
12 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
8 Explain with the aid of a sketch the action of a three-phase DOL starter
What are dashpots used for How are remote start and stop buttons connected
9 A I0 kW 240V 50Hz single-phase cage rotor induction motor is 85efficient and has a PF of 068
lagging Calculate the motor current and the value of capacitor required to raise the PF to 093
lagging
10 Calculate the torque developed by an 18 kW four-pole induction motor run at 35 slip from a
50Hz supply
APPENDIX 1
13 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 11
14 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 111
Attachment Reference
httpswwwtlc-directcoukBook621htm
httpwwwstgovmyindexphpms
15 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
TOOLS MATERIAL SPECIFICATION QUANTITY
1 Mounting board 600 x 600 x 25 mm 1
2 Triple pole MCB 20 A 415 V 1
3 Single pole MCB 6 A 240 V 1
4 Rotor Resistor set 10kW 1
5 Triple pole Contactor 240Vac 20A 4
6 Indicating light 240vac 5 A 4
7 Start stop push button 240Vac 5A 4
8 DIN rail 35 mm As required
9 Flexible wires 1 mm 2 As required
10 Single core PVC insulated wire 25 mm 2 As required
11 Terminal block 20 A As required
12 Slip Ring motor 10kW 1
13 5 pin round 3 phase socket 415V 20A 1
14 5 core flexible wire 20A 500V 2 metre
Procedures
1 Identify each component and quantity of required from the schematic diagram attached
2 Test the functionality of each component by using multi-meter or power supply whichever
applicable
3 Wire component according to circuit diagram
10 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
4 Test the functionality of completed project
a Dead circuit test b Life circuit test
5 Measure starting and running Amps
LESSON 16
TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
An installation in general will suffer damage
Damage usually occurs on the electric motor control as follows
1 Damage to the main circuit
2 Damage to the control circuit
The cause of the damage
i Overcurrent overload short circuit
ii Leakage current to ground
iii Equipment malfunction
iv The main control circuit
a Trip of main circuit protection devices fire
b Defect of motor terminal such as short circuit fire loose
v The control circuit is not functioning -
a contactor relay relay time overload relay does not work damaged burned
b Loose cable connection disconnected
Detecting and Repairing Damage
Examples of damage are as follows
i Motor does not work
ii Motor function and overload relay trips
iii Motor function but only partially functional control circuit
Methods of detecting damage
Among the known methods necessary to detect damage are as follows
1 Turn off the electricity at the main switch (main switch) in order to avoid any danger during the
work carried out to detect damage
2 Check all the protective gear that controls the motor control main circuit
11 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
3 Make sure the damage function control circuit
4 Check the control circuit according to the schematic circuit diagram of the motor control
5 Check the operation of the control circuit
Note
Use wiring that has been installed on the SYSTEM OF MOTOR CONTROL BOARD by Forward
Reverse control circuit for Star Delta to test and look for damage
SELF-ASSESSMENT QUESTIONS
1 (a) Explain what is meant by the term lsquoback emfrsquo in a motor
(b) Outline the basic differences between series shunt and compound wound dc motors
2 (a) With the aid of diagrams explain how the speed of series shunt and compound-wound motors
may be controlled
(b) A 440V dc shunt-wound motor has a field resistance of 200R and an armature resistance of 06 R
When its speed is 20 rev d second the current drawn from the supply is 122A Calculate its back
emf at this speed If the speed were decreased to 19 revssecond the field flux remaining unchanged
calculate the new back emf and the new armature current
3 A load of 64 kW at 240 V is supplied from the terminals of a shunt-wound dc generator The field
resistance is 180 A Calculate the armature current
4 (a) Explain with the aid of a diagram how a rotating magnetic field may be
(b) What is meant by lsquosynchronous speedrsquo
Calculate the synchronous obtained speed of a 12 pole motor if the supply frequency is 50Hz
5 (a) Explain the action of a synchronous motor
(b) What methods are available to start a synchronous motor Explain with diagrams
6 (a) Explain the action of a cage induction motor
(b) What is meant by the term lsquosliprsquo
Calculate the percentage slip of a six pole induction motor running at 162 revssecond from a 50 Hz
supply
7 Describe with sketches three different ways of starting a single-phase induction motor
12 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
8 Explain with the aid of a sketch the action of a three-phase DOL starter
What are dashpots used for How are remote start and stop buttons connected
9 A I0 kW 240V 50Hz single-phase cage rotor induction motor is 85efficient and has a PF of 068
lagging Calculate the motor current and the value of capacitor required to raise the PF to 093
lagging
10 Calculate the torque developed by an 18 kW four-pole induction motor run at 35 slip from a
50Hz supply
APPENDIX 1
13 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 11
14 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 111
Attachment Reference
httpswwwtlc-directcoukBook621htm
httpwwwstgovmyindexphpms
15 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
4 Test the functionality of completed project
a Dead circuit test b Life circuit test
5 Measure starting and running Amps
LESSON 16
TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
An installation in general will suffer damage
Damage usually occurs on the electric motor control as follows
1 Damage to the main circuit
2 Damage to the control circuit
The cause of the damage
i Overcurrent overload short circuit
ii Leakage current to ground
iii Equipment malfunction
iv The main control circuit
a Trip of main circuit protection devices fire
b Defect of motor terminal such as short circuit fire loose
v The control circuit is not functioning -
a contactor relay relay time overload relay does not work damaged burned
b Loose cable connection disconnected
Detecting and Repairing Damage
Examples of damage are as follows
i Motor does not work
ii Motor function and overload relay trips
iii Motor function but only partially functional control circuit
Methods of detecting damage
Among the known methods necessary to detect damage are as follows
1 Turn off the electricity at the main switch (main switch) in order to avoid any danger during the
work carried out to detect damage
2 Check all the protective gear that controls the motor control main circuit
11 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
3 Make sure the damage function control circuit
4 Check the control circuit according to the schematic circuit diagram of the motor control
5 Check the operation of the control circuit
Note
Use wiring that has been installed on the SYSTEM OF MOTOR CONTROL BOARD by Forward
Reverse control circuit for Star Delta to test and look for damage
SELF-ASSESSMENT QUESTIONS
1 (a) Explain what is meant by the term lsquoback emfrsquo in a motor
(b) Outline the basic differences between series shunt and compound wound dc motors
2 (a) With the aid of diagrams explain how the speed of series shunt and compound-wound motors
may be controlled
(b) A 440V dc shunt-wound motor has a field resistance of 200R and an armature resistance of 06 R
When its speed is 20 rev d second the current drawn from the supply is 122A Calculate its back
emf at this speed If the speed were decreased to 19 revssecond the field flux remaining unchanged
calculate the new back emf and the new armature current
3 A load of 64 kW at 240 V is supplied from the terminals of a shunt-wound dc generator The field
resistance is 180 A Calculate the armature current
4 (a) Explain with the aid of a diagram how a rotating magnetic field may be
(b) What is meant by lsquosynchronous speedrsquo
Calculate the synchronous obtained speed of a 12 pole motor if the supply frequency is 50Hz
5 (a) Explain the action of a synchronous motor
(b) What methods are available to start a synchronous motor Explain with diagrams
6 (a) Explain the action of a cage induction motor
(b) What is meant by the term lsquosliprsquo
Calculate the percentage slip of a six pole induction motor running at 162 revssecond from a 50 Hz
supply
7 Describe with sketches three different ways of starting a single-phase induction motor
12 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
8 Explain with the aid of a sketch the action of a three-phase DOL starter
What are dashpots used for How are remote start and stop buttons connected
9 A I0 kW 240V 50Hz single-phase cage rotor induction motor is 85efficient and has a PF of 068
lagging Calculate the motor current and the value of capacitor required to raise the PF to 093
lagging
10 Calculate the torque developed by an 18 kW four-pole induction motor run at 35 slip from a
50Hz supply
APPENDIX 1
13 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 11
14 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 111
Attachment Reference
httpswwwtlc-directcoukBook621htm
httpwwwstgovmyindexphpms
15 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
3 Make sure the damage function control circuit
4 Check the control circuit according to the schematic circuit diagram of the motor control
5 Check the operation of the control circuit
Note
Use wiring that has been installed on the SYSTEM OF MOTOR CONTROL BOARD by Forward
Reverse control circuit for Star Delta to test and look for damage
SELF-ASSESSMENT QUESTIONS
1 (a) Explain what is meant by the term lsquoback emfrsquo in a motor
(b) Outline the basic differences between series shunt and compound wound dc motors
2 (a) With the aid of diagrams explain how the speed of series shunt and compound-wound motors
may be controlled
(b) A 440V dc shunt-wound motor has a field resistance of 200R and an armature resistance of 06 R
When its speed is 20 rev d second the current drawn from the supply is 122A Calculate its back
emf at this speed If the speed were decreased to 19 revssecond the field flux remaining unchanged
calculate the new back emf and the new armature current
3 A load of 64 kW at 240 V is supplied from the terminals of a shunt-wound dc generator The field
resistance is 180 A Calculate the armature current
4 (a) Explain with the aid of a diagram how a rotating magnetic field may be
(b) What is meant by lsquosynchronous speedrsquo
Calculate the synchronous obtained speed of a 12 pole motor if the supply frequency is 50Hz
5 (a) Explain the action of a synchronous motor
(b) What methods are available to start a synchronous motor Explain with diagrams
6 (a) Explain the action of a cage induction motor
(b) What is meant by the term lsquosliprsquo
Calculate the percentage slip of a six pole induction motor running at 162 revssecond from a 50 Hz
supply
7 Describe with sketches three different ways of starting a single-phase induction motor
12 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
8 Explain with the aid of a sketch the action of a three-phase DOL starter
What are dashpots used for How are remote start and stop buttons connected
9 A I0 kW 240V 50Hz single-phase cage rotor induction motor is 85efficient and has a PF of 068
lagging Calculate the motor current and the value of capacitor required to raise the PF to 093
lagging
10 Calculate the torque developed by an 18 kW four-pole induction motor run at 35 slip from a
50Hz supply
APPENDIX 1
13 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 11
14 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 111
Attachment Reference
httpswwwtlc-directcoukBook621htm
httpwwwstgovmyindexphpms
15 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
8 Explain with the aid of a sketch the action of a three-phase DOL starter
What are dashpots used for How are remote start and stop buttons connected
9 A I0 kW 240V 50Hz single-phase cage rotor induction motor is 85efficient and has a PF of 068
lagging Calculate the motor current and the value of capacitor required to raise the PF to 093
lagging
10 Calculate the torque developed by an 18 kW four-pole induction motor run at 35 slip from a
50Hz supply
APPENDIX 1
13 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 11
14 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 111
Attachment Reference
httpswwwtlc-directcoukBook621htm
httpwwwstgovmyindexphpms
15 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 11
14 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 111
Attachment Reference
httpswwwtlc-directcoukBook621htm
httpwwwstgovmyindexphpms
15 ndash 99EASYTECH ENTERPRISE
EZTECH ELECTRICAL INSTALLATION GUIDE
APPENDIX 111
Attachment Reference
httpswwwtlc-directcoukBook621htm
httpwwwstgovmyindexphpms
15 ndash 99EASYTECH ENTERPRISE