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EZTECH EASYTECH SDN BHD DOMESTIC AND INDUSTRIAL WIRING INSTALLATION GUIDE PREPARED BY EASYTECH

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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

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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

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Legal Requirements

Regulation 11(1) of the Electricity Regulations 1994 states that all wiring or rewiring of an

installation or extension to an existing installation which shall be carried out by an Electrical

Contractor or a Private Wiring Unit have to obtain the approval in writing from a licensee or supply

authority

1 Planning of Electrical Wiring Work

Prior to carrying out wiring work the 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

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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

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EZTECH ELECTRICAL INSTALLATION GUIDE

2 CONTROL AND PROTECTION SYSTEM FOR ELECTRICAL WIRING

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EZTECH ELECTRICAL INSTALLATION GUIDE

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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

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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

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iii The selected cable must be capable of delivering the electrical energy efficiently

iv The cable size allows it to carry the current without heating the cable

v The voltage drop must not exceed 4 of the supply voltage Refer to Table 4D1B in Appendix III

vi The cable insulation must be suitable for the surrounding conditions of the installation such as the

ability to withstand the surrounding temperatures and the ability to provide mechanical protection

vii Each conductor in the installation must be protected from overcurrent by means of overcurrent

protection devices needed to prevent damage to the cable insulation

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

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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 -

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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

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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

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This is the conductor which is connected between the consumer earthing point and the exposed

metallic part The minimum cable size for this purpose is 10 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

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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

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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

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Direct contact occurs when the worker or consumer receives an electrical shock on touching directly a

live conductor or cable

b Indirect Contact

Here the electric shock occurs due to contact with a part which is connected to the electrical

installation and not to a direct contact with a live cable or conductor possibly due to damages in the

appliance or insulation resulting in leakages of current

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

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A first aid box has to be provided by the building owner construction site supervisor or brought

personally by the worker under the supervision of the responsible person

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

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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

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3 In operation the Main Contactor (KM3) and the Star Contactor (KM1) are closed initially and

then after a period of time the star contactor is opened and then the delta contactor (KM2) is

closed The control of the contactors is by the timer (K1T) built into the starter The Star and Delta

are electrically interlocked and preferably mechanically interlocked as well In effect there are

four states

4 The star contactor serves to initially short the secondary terminal of the motor U2 V2 W2 for the

start sequence during the initial run of the motor from standstill This provides one third of DOL

current to the motor thus reducing the high inrush current inherent with large capacity motors at

startup

5 Controlling the interchanging star connection and delta connection of an AC induction motor is

achieved by means of a star delta or wye delta control circuit The control circuit consists of push

button switches auxiliary contacts and a timer

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

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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

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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

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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

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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

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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

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EZTECH ELECTRICAL INSTALLATION GUIDE

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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

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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

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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

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EZTECH ELECTRICAL INSTALLATION GUIDE

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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

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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

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EZTECH ELECTRICAL INSTALLATION GUIDE

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EZTECH ELECTRICAL INSTALLATION GUIDE

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EZTECH ELECTRICAL INSTALLATION GUIDE

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EZTECH ELECTRICAL INSTALLATION GUIDE

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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

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EZTECH ELECTRICAL INSTALLATION GUIDE

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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

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61 ndash 99EASYTECH ENTERPRISE

EZTECH ELECTRICAL INSTALLATION GUIDE

Insulation resitance test

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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

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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

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Polarity test

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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

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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

  • ELECTRICITY SUPPLY SPECIFICATIONS
    • Legal Requirements
    • Determining Consumer Load Requirements
    • 2 CONTROL AND PROTECTION SYSTEM FOR ELECTRICAL WIRING
    • CABLE SELECTION
      • 32 Factors Related to Cable Current Carrying Capacity
      • Functions and Colour Identification of Non Flexible Cables
        • Conductor Insulation and Types of Wiring
        • Functions and Colour Identification of Non Flexible Cables
        • 3 SELECTION OF WIRING ACCESSORIES
        • EARTHING OF ELECTRICAL INSTALLATIONS
          • 4 SAFETY REQUIREMENTS FOR ELECTRICAL WIRING WORKS IN RESIDENTIAL BUILDINGS
            • Why Electric Shocks Occur
            • INSTALLATION CIRCUITS AND SYSTEMS
            • Working Principal of Star-Delta Starter
            • Star-delta Starter Consists following units
            • Power Circuit of Star Delta Starter
            • Control Circuit of Star-Delta Starter (Open Transition)
            • What is Open or Closed Transition Starting
            • Effect of Transient in Starter (Open Transient starter)
            • Size of each part of Star-Delta starter
            • Motor Starting Characteristics of Star-Delta Starter
            • Advantages of Star-Delta starter
            • Disadvantages of Star-Delta starter
            • Features of star-delta starting
            • Application of Star-Delta Starter
            • LESSON 1 WIRING SYSTEM OF SINGLE PHASE DISTRIBUTION BOARD
            • LESSON 2 WIRING SYSTEM OF SINGLE PHASE LIGHTING CIRCUIT
            • LESSON 3ndash WIRING SYSTEM OF SINGLE PHASE POWER CIRCUIT
            • LESSON 4ndash CONDUIT BENDING AND TRUNKING FABRICATION TECHNIQUE
            • LESSON 5 ndashWIRING SYSTEM OF 1 Oslash LIGHTING AND POWER CIRCUIT
              • POWER CIRCUITS
                • LESSON 6 ndash WIRING SYSTEM OF 3 Oslash DISTRIBUTION BOARD
                • LESSON 7 ndash WIRING SYSTEM OF THREE PHASE LIGHTING AND POWER CIRCUIT
                • LESSON 8 INSPECTION AND TESTING OF ELECTRICAL INSTALLATION
                  • CONTINUITY TEST
                    • Polarity Test
                      • Earth Electrode Resistance Test
                      • Earth Electrode Resistance Measurement Method (Figure 86)
                        • Residual Current Device Test
                        • LESSON 9 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (DC)
                        • LESSON 10 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (AC)
                        • LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE
                        • LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
                          • LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
                          • LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
                          • LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
                            • a Dead circuit test
                            • b Life circuit test
                            • LESSON 16
                              • TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
                              • SELF-ASSESSMENT QUESTIONS
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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

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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

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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

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Legal Requirements

Regulation 11(1) of the Electricity Regulations 1994 states that all wiring or rewiring of an

installation or extension to an existing installation which shall be carried out by an Electrical

Contractor or a Private Wiring Unit have to obtain the approval in writing from a licensee or supply

authority

1 Planning of Electrical Wiring Work

Prior to carrying out wiring work the 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

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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

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2 CONTROL AND PROTECTION SYSTEM FOR ELECTRICAL WIRING

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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

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The circuit breakers or fuses must be installed on the live conductors only For three phase circuits all

the circuit breakers or fuses must be combined in one set of circuits

Selection of over current devices must be based on the short circuit fault current levels of the circuit

breaker or main switch (kA)

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

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iii The selected cable must be capable of delivering the electrical energy efficiently

iv The cable size allows it to carry the current without heating the cable

v The voltage drop must not exceed 4 of the supply voltage Refer to Table 4D1B in Appendix III

vi The cable insulation must be suitable for the surrounding conditions of the installation such as the

ability to withstand the surrounding temperatures and the ability to provide mechanical protection

vii Each conductor in the installation must be protected from overcurrent by means of overcurrent

protection devices needed to prevent damage to the cable insulation

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

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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 -

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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

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The motor starter shall be of Direct-On-Line type with the appliance together with the contactor

overload relay and on-off control The circuit 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

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This is the conductor which is connected between the consumer earthing point and the exposed

metallic part The minimum cable size for this purpose is 10 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

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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

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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

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Direct contact occurs when the worker or consumer receives an electrical shock on touching directly a

live conductor or cable

b Indirect Contact

Here the electric shock occurs due to contact with a part which is connected to the electrical

installation and not to a direct contact with a live cable or conductor possibly due to damages in the

appliance or insulation resulting in leakages of current

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

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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

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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

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3 In operation the Main Contactor (KM3) and the Star Contactor (KM1) are closed initially and

then after a period of time the star contactor is opened and then the delta contactor (KM2) is

closed The control of the contactors is by the timer (K1T) built into the starter The Star and Delta

are electrically interlocked and preferably mechanically interlocked as well In effect there are

four states

4 The star contactor serves to initially short the secondary terminal of the motor U2 V2 W2 for the

start sequence during the initial run of the motor from standstill This provides one third of DOL

current to the motor thus reducing the high inrush current inherent with large capacity motors at

startup

5 Controlling the interchanging star connection and delta connection of an AC induction motor is

achieved by means of a star delta or wye delta control circuit The control circuit consists of push

button switches auxiliary contacts and a timer

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

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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

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Closed Transition State The Main [KM3] contactor is closed and the Delta [KM2] and Star

[KM1] contactors are open Current flows through the motor windings and the transition resistors

via KM4

Delta State The Main and the Delta contactors are closed The transition resistors are shorted out

The Star contactor is open The motor is connected to full line voltage and full power and torque

are available

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

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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

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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

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EZTECH ELECTRICAL INSTALLATION GUIDE

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EZTECH ELECTRICAL INSTALLATION GUIDE

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EZTECH ELECTRICAL INSTALLATION GUIDE

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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

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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

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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

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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

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EZTECH ELECTRICAL INSTALLATION GUIDE

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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)

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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

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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

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EZTECH ELECTRICAL INSTALLATION GUIDE

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EZTECH ELECTRICAL INSTALLATION GUIDE

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EZTECH ELECTRICAL INSTALLATION GUIDE

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EZTECH ELECTRICAL INSTALLATION GUIDE

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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

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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

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EZTECH ELECTRICAL INSTALLATION GUIDE

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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

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61 ndash 99EASYTECH ENTERPRISE

EZTECH ELECTRICAL INSTALLATION GUIDE

Insulation resitance test

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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

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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

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Polarity test

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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

  • ELECTRICITY SUPPLY SPECIFICATIONS
    • Legal Requirements
    • Determining Consumer Load Requirements
    • 2 CONTROL AND PROTECTION SYSTEM FOR ELECTRICAL WIRING
    • CABLE SELECTION
      • 32 Factors Related to Cable Current Carrying Capacity
      • Functions and Colour Identification of Non Flexible Cables
        • Conductor Insulation and Types of Wiring
        • Functions and Colour Identification of Non Flexible Cables
        • 3 SELECTION OF WIRING ACCESSORIES
        • EARTHING OF ELECTRICAL INSTALLATIONS
          • 4 SAFETY REQUIREMENTS FOR ELECTRICAL WIRING WORKS IN RESIDENTIAL BUILDINGS
            • Why Electric Shocks Occur
            • INSTALLATION CIRCUITS AND SYSTEMS
            • Working Principal of Star-Delta Starter
            • Star-delta Starter Consists following units
            • Power Circuit of Star Delta Starter
            • Control Circuit of Star-Delta Starter (Open Transition)
            • What is Open or Closed Transition Starting
            • Effect of Transient in Starter (Open Transient starter)
            • Size of each part of Star-Delta starter
            • Motor Starting Characteristics of Star-Delta Starter
            • Advantages of Star-Delta starter
            • Disadvantages of Star-Delta starter
            • Features of star-delta starting
            • Application of Star-Delta Starter
            • LESSON 1 WIRING SYSTEM OF SINGLE PHASE DISTRIBUTION BOARD
            • LESSON 2 WIRING SYSTEM OF SINGLE PHASE LIGHTING CIRCUIT
            • LESSON 3ndash WIRING SYSTEM OF SINGLE PHASE POWER CIRCUIT
            • LESSON 4ndash CONDUIT BENDING AND TRUNKING FABRICATION TECHNIQUE
            • LESSON 5 ndashWIRING SYSTEM OF 1 Oslash LIGHTING AND POWER CIRCUIT
              • POWER CIRCUITS
                • LESSON 6 ndash WIRING SYSTEM OF 3 Oslash DISTRIBUTION BOARD
                • LESSON 7 ndash WIRING SYSTEM OF THREE PHASE LIGHTING AND POWER CIRCUIT
                • LESSON 8 INSPECTION AND TESTING OF ELECTRICAL INSTALLATION
                  • CONTINUITY TEST
                    • Polarity Test
                      • Earth Electrode Resistance Test
                      • Earth Electrode Resistance Measurement Method (Figure 86)
                        • Residual Current Device Test
                        • LESSON 9 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (DC)
                        • LESSON 10 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (AC)
                        • LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE
                        • LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
                          • LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
                          • LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
                          • LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
                            • a Dead circuit test
                            • b Life circuit test
                            • LESSON 16
                              • TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
                              • SELF-ASSESSMENT QUESTIONS
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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

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ELECTRICITY SUPPLY SPECIFICATIONS

Electricity supply for domestic consumers according to MS IEC 60038 standards meets the

following specifications -

i Single phase supply with nominal voltage of 230V range +10 -6

ii Three phase supply with nominal voltage of 400V range +10 -6

iii Permitted frequency is 50Hz + 1

iv Earthing system type (TT System) as in Figure 21 and Figure 22

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Legal Requirements

Regulation 11(1) of the Electricity Regulations 1994 states that all wiring or rewiring of an

installation or extension to an existing installation which shall be carried out by an Electrical

Contractor or a Private Wiring Unit have to obtain the approval in writing from a licensee or supply

authority

1 Planning of Electrical Wiring Work

Prior to carrying out wiring work the 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

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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

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2 CONTROL AND PROTECTION SYSTEM FOR ELECTRICAL WIRING

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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

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The circuit breakers or fuses must be installed on the live conductors only For three phase circuits all

the circuit breakers or fuses must be combined in one set of circuits

Selection of over current devices must be based on the short circuit fault current levels of the circuit

breaker or main switch (kA)

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

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iii The selected cable must be capable of delivering the electrical energy efficiently

iv The cable size allows it to carry the current without heating the cable

v The voltage drop must not exceed 4 of the supply voltage Refer to Table 4D1B in Appendix III

vi The cable insulation must be suitable for the surrounding conditions of the installation such as the

ability to withstand the surrounding temperatures and the ability to provide mechanical protection

vii Each conductor in the installation must be protected from overcurrent by means of overcurrent

protection devices needed to prevent damage to the cable insulation

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

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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

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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 -

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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

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The motor starter shall be of Direct-On-Line type with the appliance together with the contactor

overload relay and on-off control The circuit 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

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This is the conductor which is connected between the consumer earthing point and the exposed

metallic part The minimum cable size for this purpose is 10 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

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iv Small metallic parts such as screws and name plates which are isolated by means of insulation

v Metallic lamp parts for filament lamps in water proof floors

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

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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

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Direct contact occurs when the worker or consumer receives an electrical shock on touching directly a

live conductor or cable

b Indirect Contact

Here the electric shock occurs due to contact with a part which is connected to the electrical

installation and not to a direct contact with a live cable or conductor possibly due to damages in the

appliance or insulation resulting in leakages of current

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

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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

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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

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3 In operation the Main Contactor (KM3) and the Star Contactor (KM1) are closed initially and

then after a period of time the star contactor is opened and then the delta contactor (KM2) is

closed The control of the contactors is by the timer (K1T) built into the starter The Star and Delta

are electrically interlocked and preferably mechanically interlocked as well In effect there are

four states

4 The star contactor serves to initially short the secondary terminal of the motor U2 V2 W2 for the

start sequence during the initial run of the motor from standstill This provides one third of DOL

current to the motor thus reducing the high inrush current inherent with large capacity motors at

startup

5 Controlling the interchanging star connection and delta connection of an AC induction motor is

achieved by means of a star delta or wye delta control circuit The control circuit consists of push

button switches auxiliary contacts and a timer

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

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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

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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

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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

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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

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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

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EZTECH ELECTRICAL INSTALLATION GUIDE

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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

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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

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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

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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

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EZTECH ELECTRICAL INSTALLATION GUIDE

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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)

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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

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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

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EZTECH ELECTRICAL INSTALLATION GUIDE

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EZTECH ELECTRICAL INSTALLATION GUIDE

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EZTECH ELECTRICAL INSTALLATION GUIDE

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EZTECH ELECTRICAL INSTALLATION GUIDE

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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

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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

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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

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EZTECH ELECTRICAL INSTALLATION GUIDE

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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

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61 ndash 99EASYTECH ENTERPRISE

EZTECH ELECTRICAL INSTALLATION GUIDE

Insulation resitance test

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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

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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

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Polarity test

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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

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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

  • ELECTRICITY SUPPLY SPECIFICATIONS
    • Legal Requirements
    • Determining Consumer Load Requirements
    • 2 CONTROL AND PROTECTION SYSTEM FOR ELECTRICAL WIRING
    • CABLE SELECTION
      • 32 Factors Related to Cable Current Carrying Capacity
      • Functions and Colour Identification of Non Flexible Cables
        • Conductor Insulation and Types of Wiring
        • Functions and Colour Identification of Non Flexible Cables
        • 3 SELECTION OF WIRING ACCESSORIES
        • EARTHING OF ELECTRICAL INSTALLATIONS
          • 4 SAFETY REQUIREMENTS FOR ELECTRICAL WIRING WORKS IN RESIDENTIAL BUILDINGS
            • Why Electric Shocks Occur
            • INSTALLATION CIRCUITS AND SYSTEMS
            • Working Principal of Star-Delta Starter
            • Star-delta Starter Consists following units
            • Power Circuit of Star Delta Starter
            • Control Circuit of Star-Delta Starter (Open Transition)
            • What is Open or Closed Transition Starting
            • Effect of Transient in Starter (Open Transient starter)
            • Size of each part of Star-Delta starter
            • Motor Starting Characteristics of Star-Delta Starter
            • Advantages of Star-Delta starter
            • Disadvantages of Star-Delta starter
            • Features of star-delta starting
            • Application of Star-Delta Starter
            • LESSON 1 WIRING SYSTEM OF SINGLE PHASE DISTRIBUTION BOARD
            • LESSON 2 WIRING SYSTEM OF SINGLE PHASE LIGHTING CIRCUIT
            • LESSON 3ndash WIRING SYSTEM OF SINGLE PHASE POWER CIRCUIT
            • LESSON 4ndash CONDUIT BENDING AND TRUNKING FABRICATION TECHNIQUE
            • LESSON 5 ndashWIRING SYSTEM OF 1 Oslash LIGHTING AND POWER CIRCUIT
              • POWER CIRCUITS
                • LESSON 6 ndash WIRING SYSTEM OF 3 Oslash DISTRIBUTION BOARD
                • LESSON 7 ndash WIRING SYSTEM OF THREE PHASE LIGHTING AND POWER CIRCUIT
                • LESSON 8 INSPECTION AND TESTING OF ELECTRICAL INSTALLATION
                  • CONTINUITY TEST
                    • Polarity Test
                      • Earth Electrode Resistance Test
                      • Earth Electrode Resistance Measurement Method (Figure 86)
                        • Residual Current Device Test
                        • LESSON 9 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (DC)
                        • LESSON 10 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (AC)
                        • LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE
                        • LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
                          • LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
                          • LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
                          • LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
                            • a Dead circuit test
                            • b Life circuit test
                            • LESSON 16
                              • TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
                              • SELF-ASSESSMENT QUESTIONS
Page 4: WorksheetTask AMIN

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

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Legal Requirements

Regulation 11(1) of the Electricity Regulations 1994 states that all wiring or rewiring of an

installation or extension to an existing installation which shall be carried out by an Electrical

Contractor or a Private Wiring Unit have to obtain the approval in writing from a licensee or supply

authority

1 Planning of Electrical Wiring Work

Prior to carrying out wiring work the 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

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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

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2 CONTROL AND PROTECTION SYSTEM FOR ELECTRICAL WIRING

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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

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The circuit breakers or fuses must be installed on the live conductors only For three phase circuits all

the circuit breakers or fuses must be combined in one set of circuits

Selection of over current devices must be based on the short circuit fault current levels of the circuit

breaker or main switch (kA)

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

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iii The selected cable must be capable of delivering the electrical energy efficiently

iv The cable size allows it to carry the current without heating the cable

v The voltage drop must not exceed 4 of the supply voltage Refer to Table 4D1B in Appendix III

vi The cable insulation must be suitable for the surrounding conditions of the installation such as the

ability to withstand the surrounding temperatures and the ability to provide mechanical protection

vii Each conductor in the installation must be protected from overcurrent by means of overcurrent

protection devices needed to prevent damage to the cable insulation

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

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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

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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 -

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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

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The motor starter shall be of Direct-On-Line type with the appliance together with the contactor

overload relay and on-off control The circuit 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

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This is the conductor which is connected between the consumer earthing point and the exposed

metallic part The minimum cable size for this purpose is 10 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

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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

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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

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Direct contact occurs when the worker or consumer receives an electrical shock on touching directly a

live conductor or cable

b Indirect Contact

Here the electric shock occurs due to contact with a part which is connected to the electrical

installation and not to a direct contact with a live cable or conductor possibly due to damages in the

appliance or insulation resulting in leakages of current

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

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A first aid box has to be provided by the building owner construction site supervisor or brought

personally by the worker under the supervision of the responsible person

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

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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

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3 In operation the Main Contactor (KM3) and the Star Contactor (KM1) are closed initially and

then after a period of time the star contactor is opened and then the delta contactor (KM2) is

closed The control of the contactors is by the timer (K1T) built into the starter The Star and Delta

are electrically interlocked and preferably mechanically interlocked as well In effect there are

four states

4 The star contactor serves to initially short the secondary terminal of the motor U2 V2 W2 for the

start sequence during the initial run of the motor from standstill This provides one third of DOL

current to the motor thus reducing the high inrush current inherent with large capacity motors at

startup

5 Controlling the interchanging star connection and delta connection of an AC induction motor is

achieved by means of a star delta or wye delta control circuit The control circuit consists of push

button switches auxiliary contacts and a timer

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

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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

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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

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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

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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

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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

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EZTECH ELECTRICAL INSTALLATION GUIDE

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EZTECH ELECTRICAL INSTALLATION GUIDE

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EZTECH ELECTRICAL INSTALLATION GUIDE

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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

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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

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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

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EZTECH ELECTRICAL INSTALLATION GUIDE

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EZTECH ELECTRICAL INSTALLATION GUIDE

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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)

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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

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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

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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

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EZTECH ELECTRICAL INSTALLATION GUIDE

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EZTECH ELECTRICAL INSTALLATION GUIDE

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EZTECH ELECTRICAL INSTALLATION GUIDE

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EZTECH ELECTRICAL INSTALLATION GUIDE

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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

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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

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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

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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

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61 ndash 99EASYTECH ENTERPRISE

EZTECH ELECTRICAL INSTALLATION GUIDE

Insulation resitance test

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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

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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

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Polarity test

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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

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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

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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

  • ELECTRICITY SUPPLY SPECIFICATIONS
    • Legal Requirements
    • Determining Consumer Load Requirements
    • 2 CONTROL AND PROTECTION SYSTEM FOR ELECTRICAL WIRING
    • CABLE SELECTION
      • 32 Factors Related to Cable Current Carrying Capacity
      • Functions and Colour Identification of Non Flexible Cables
        • Conductor Insulation and Types of Wiring
        • Functions and Colour Identification of Non Flexible Cables
        • 3 SELECTION OF WIRING ACCESSORIES
        • EARTHING OF ELECTRICAL INSTALLATIONS
          • 4 SAFETY REQUIREMENTS FOR ELECTRICAL WIRING WORKS IN RESIDENTIAL BUILDINGS
            • Why Electric Shocks Occur
            • INSTALLATION CIRCUITS AND SYSTEMS
            • Working Principal of Star-Delta Starter
            • Star-delta Starter Consists following units
            • Power Circuit of Star Delta Starter
            • Control Circuit of Star-Delta Starter (Open Transition)
            • What is Open or Closed Transition Starting
            • Effect of Transient in Starter (Open Transient starter)
            • Size of each part of Star-Delta starter
            • Motor Starting Characteristics of Star-Delta Starter
            • Advantages of Star-Delta starter
            • Disadvantages of Star-Delta starter
            • Features of star-delta starting
            • Application of Star-Delta Starter
            • LESSON 1 WIRING SYSTEM OF SINGLE PHASE DISTRIBUTION BOARD
            • LESSON 2 WIRING SYSTEM OF SINGLE PHASE LIGHTING CIRCUIT
            • LESSON 3ndash WIRING SYSTEM OF SINGLE PHASE POWER CIRCUIT
            • LESSON 4ndash CONDUIT BENDING AND TRUNKING FABRICATION TECHNIQUE
            • LESSON 5 ndashWIRING SYSTEM OF 1 Oslash LIGHTING AND POWER CIRCUIT
              • POWER CIRCUITS
                • LESSON 6 ndash WIRING SYSTEM OF 3 Oslash DISTRIBUTION BOARD
                • LESSON 7 ndash WIRING SYSTEM OF THREE PHASE LIGHTING AND POWER CIRCUIT
                • LESSON 8 INSPECTION AND TESTING OF ELECTRICAL INSTALLATION
                  • CONTINUITY TEST
                    • Polarity Test
                      • Earth Electrode Resistance Test
                      • Earth Electrode Resistance Measurement Method (Figure 86)
                        • Residual Current Device Test
                        • LESSON 9 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (DC)
                        • LESSON 10 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (AC)
                        • LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE
                        • LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
                          • LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
                          • LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
                          • LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
                            • a Dead circuit test
                            • b Life circuit test
                            • LESSON 16
                              • TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
                              • SELF-ASSESSMENT QUESTIONS
Page 5: WorksheetTask AMIN

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

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2 CONTROL AND PROTECTION SYSTEM FOR ELECTRICAL WIRING

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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

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The circuit breakers or fuses must be installed on the live conductors only For three phase circuits all

the circuit breakers or fuses must be combined in one set of circuits

Selection of over current devices must be based on the short circuit fault current levels of the circuit

breaker or main switch (kA)

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

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iii The selected cable must be capable of delivering the electrical energy efficiently

iv The cable size allows it to carry the current without heating the cable

v The voltage drop must not exceed 4 of the supply voltage Refer to Table 4D1B in Appendix III

vi The cable insulation must be suitable for the surrounding conditions of the installation such as the

ability to withstand the surrounding temperatures and the ability to provide mechanical protection

vii Each conductor in the installation must be protected from overcurrent by means of overcurrent

protection devices needed to prevent damage to the cable insulation

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

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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

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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 -

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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

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The motor starter shall be of Direct-On-Line type with the appliance together with the contactor

overload relay and on-off control The circuit 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

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This is the conductor which is connected between the consumer earthing point and the exposed

metallic part The minimum cable size for this purpose is 10 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

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iv Small metallic parts such as screws and name plates which are isolated by means of insulation

v Metallic lamp parts for filament lamps in water proof floors

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

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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

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Direct contact occurs when the worker or consumer receives an electrical shock on touching directly a

live conductor or cable

b Indirect Contact

Here the electric shock occurs due to contact with a part which is connected to the electrical

installation and not to a direct contact with a live cable or conductor possibly due to damages in the

appliance or insulation resulting in leakages of current

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

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A first aid box has to be provided by the building owner construction site supervisor or brought

personally by the worker under the supervision of the responsible person

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

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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

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3 In operation the Main Contactor (KM3) and the Star Contactor (KM1) are closed initially and

then after a period of time the star contactor is opened and then the delta contactor (KM2) is

closed The control of the contactors is by the timer (K1T) built into the starter The Star and Delta

are electrically interlocked and preferably mechanically interlocked as well In effect there are

four states

4 The star contactor serves to initially short the secondary terminal of the motor U2 V2 W2 for the

start sequence during the initial run of the motor from standstill This provides one third of DOL

current to the motor thus reducing the high inrush current inherent with large capacity motors at

startup

5 Controlling the interchanging star connection and delta connection of an AC induction motor is

achieved by means of a star delta or wye delta control circuit The control circuit consists of push

button switches auxiliary contacts and a timer

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

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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

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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

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Closed Transition State The Main [KM3] contactor is closed and the Delta [KM2] and Star

[KM1] contactors are open Current flows through the motor windings and the transition resistors

via KM4

Delta State The Main and the Delta contactors are closed The transition resistors are shorted out

The Star contactor is open The motor is connected to full line voltage and full power and torque

are available

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

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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

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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

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EZTECH ELECTRICAL INSTALLATION GUIDE

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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

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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

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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

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EZTECH ELECTRICAL INSTALLATION GUIDE

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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

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EZTECH ELECTRICAL INSTALLATION GUIDE

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EZTECH ELECTRICAL INSTALLATION GUIDE

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EZTECH ELECTRICAL INSTALLATION GUIDE

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EZTECH ELECTRICAL INSTALLATION GUIDE

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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

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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

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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

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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

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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

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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

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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

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61 ndash 99EASYTECH ENTERPRISE

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Insulation resitance test

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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

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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

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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

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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

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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

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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

  • ELECTRICITY SUPPLY SPECIFICATIONS
    • Legal Requirements
    • Determining Consumer Load Requirements
    • 2 CONTROL AND PROTECTION SYSTEM FOR ELECTRICAL WIRING
    • CABLE SELECTION
      • 32 Factors Related to Cable Current Carrying Capacity
      • Functions and Colour Identification of Non Flexible Cables
        • Conductor Insulation and Types of Wiring
        • Functions and Colour Identification of Non Flexible Cables
        • 3 SELECTION OF WIRING ACCESSORIES
        • EARTHING OF ELECTRICAL INSTALLATIONS
          • 4 SAFETY REQUIREMENTS FOR ELECTRICAL WIRING WORKS IN RESIDENTIAL BUILDINGS
            • Why Electric Shocks Occur
            • INSTALLATION CIRCUITS AND SYSTEMS
            • Working Principal of Star-Delta Starter
            • Star-delta Starter Consists following units
            • Power Circuit of Star Delta Starter
            • Control Circuit of Star-Delta Starter (Open Transition)
            • What is Open or Closed Transition Starting
            • Effect of Transient in Starter (Open Transient starter)
            • Size of each part of Star-Delta starter
            • Motor Starting Characteristics of Star-Delta Starter
            • Advantages of Star-Delta starter
            • Disadvantages of Star-Delta starter
            • Features of star-delta starting
            • Application of Star-Delta Starter
            • LESSON 1 WIRING SYSTEM OF SINGLE PHASE DISTRIBUTION BOARD
            • LESSON 2 WIRING SYSTEM OF SINGLE PHASE LIGHTING CIRCUIT
            • LESSON 3ndash WIRING SYSTEM OF SINGLE PHASE POWER CIRCUIT
            • LESSON 4ndash CONDUIT BENDING AND TRUNKING FABRICATION TECHNIQUE
            • LESSON 5 ndashWIRING SYSTEM OF 1 Oslash LIGHTING AND POWER CIRCUIT
              • POWER CIRCUITS
                • LESSON 6 ndash WIRING SYSTEM OF 3 Oslash DISTRIBUTION BOARD
                • LESSON 7 ndash WIRING SYSTEM OF THREE PHASE LIGHTING AND POWER CIRCUIT
                • LESSON 8 INSPECTION AND TESTING OF ELECTRICAL INSTALLATION
                  • CONTINUITY TEST
                    • Polarity Test
                      • Earth Electrode Resistance Test
                      • Earth Electrode Resistance Measurement Method (Figure 86)
                        • Residual Current Device Test
                        • LESSON 9 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (DC)
                        • LESSON 10 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (AC)
                        • LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE
                        • LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
                          • LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
                          • LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
                          • LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
                            • a Dead circuit test
                            • b Life circuit test
                            • LESSON 16
                              • TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
                              • SELF-ASSESSMENT QUESTIONS
Page 6: WorksheetTask AMIN

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

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iii The selected cable must be capable of delivering the electrical energy efficiently

iv The cable size allows it to carry the current without heating the cable

v The voltage drop must not exceed 4 of the supply voltage Refer to Table 4D1B in Appendix III

vi The cable insulation must be suitable for the surrounding conditions of the installation such as the

ability to withstand the surrounding temperatures and the ability to provide mechanical protection

vii Each conductor in the installation must be protected from overcurrent by means of overcurrent

protection devices needed to prevent damage to the cable insulation

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

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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

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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 -

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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

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The motor starter shall be of Direct-On-Line type with the appliance together with the contactor

overload relay and on-off control The circuit 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

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This is the conductor which is connected between the consumer earthing point and the exposed

metallic part The minimum cable size for this purpose is 10 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

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iv Small metallic parts such as screws and name plates which are isolated by means of insulation

v Metallic lamp parts for filament lamps in water proof floors

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

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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

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Direct contact occurs when the worker or consumer receives an electrical shock on touching directly a

live conductor or cable

b Indirect Contact

Here the electric shock occurs due to contact with a part which is connected to the electrical

installation and not to a direct contact with a live cable or conductor possibly due to damages in the

appliance or insulation resulting in leakages of current

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

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A first aid box has to be provided by the building owner construction site supervisor or brought

personally by the worker under the supervision of the responsible person

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

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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

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3 In operation the Main Contactor (KM3) and the Star Contactor (KM1) are closed initially and

then after a period of time the star contactor is opened and then the delta contactor (KM2) is

closed The control of the contactors is by the timer (K1T) built into the starter The Star and Delta

are electrically interlocked and preferably mechanically interlocked as well In effect there are

four states

4 The star contactor serves to initially short the secondary terminal of the motor U2 V2 W2 for the

start sequence during the initial run of the motor from standstill This provides one third of DOL

current to the motor thus reducing the high inrush current inherent with large capacity motors at

startup

5 Controlling the interchanging star connection and delta connection of an AC induction motor is

achieved by means of a star delta or wye delta control circuit The control circuit consists of push

button switches auxiliary contacts and a timer

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

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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

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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

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Closed Transition State The Main [KM3] contactor is closed and the Delta [KM2] and Star

[KM1] contactors are open Current flows through the motor windings and the transition resistors

via KM4

Delta State The Main and the Delta contactors are closed The transition resistors are shorted out

The Star contactor is open The motor is connected to full line voltage and full power and torque

are available

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

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In the windings means that the overload is placed after the point where the wiring to the contactors

are split into main and delta The overload then always measures the current inside the windings

The setting of Overload Relay (In Winding) =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

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In this method of starting initially motor is connected in star and then after change over the motor

is connected in delta The delta of motor is formed in starter and not on motor terminals

High transmission and current peaks When starting up pumps and fans for example the load

torque is low at the beginning of the start and increases with the square of the speed When

reaching approx 80-85 of the motor rated speed the load torque is equal to the motor torque and

the acceleration ceases To reach the rated speed a switch over to delta position is necessary and

this will very often result in high transmission and current peaks In some cases the current peak

can reach a value that is even bigger than for a 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

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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

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EZTECH ELECTRICAL INSTALLATION GUIDE

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EZTECH ELECTRICAL INSTALLATION GUIDE

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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

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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

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EZTECH ELECTRICAL INSTALLATION GUIDE

Objectives

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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

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EZTECH ELECTRICAL INSTALLATION GUIDE

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EZTECH ELECTRICAL INSTALLATION GUIDE

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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

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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

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EZTECH ELECTRICAL INSTALLATION GUIDE

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EZTECH ELECTRICAL INSTALLATION GUIDE

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EZTECH ELECTRICAL INSTALLATION GUIDE

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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

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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

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EZTECH ELECTRICAL INSTALLATION GUIDE

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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

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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

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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

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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

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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

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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

  • ELECTRICITY SUPPLY SPECIFICATIONS
    • Legal Requirements
    • Determining Consumer Load Requirements
    • 2 CONTROL AND PROTECTION SYSTEM FOR ELECTRICAL WIRING
    • CABLE SELECTION
      • 32 Factors Related to Cable Current Carrying Capacity
      • Functions and Colour Identification of Non Flexible Cables
        • Conductor Insulation and Types of Wiring
        • Functions and Colour Identification of Non Flexible Cables
        • 3 SELECTION OF WIRING ACCESSORIES
        • EARTHING OF ELECTRICAL INSTALLATIONS
          • 4 SAFETY REQUIREMENTS FOR ELECTRICAL WIRING WORKS IN RESIDENTIAL BUILDINGS
            • Why Electric Shocks Occur
            • INSTALLATION CIRCUITS AND SYSTEMS
            • Working Principal of Star-Delta Starter
            • Star-delta Starter Consists following units
            • Power Circuit of Star Delta Starter
            • Control Circuit of Star-Delta Starter (Open Transition)
            • What is Open or Closed Transition Starting
            • Effect of Transient in Starter (Open Transient starter)
            • Size of each part of Star-Delta starter
            • Motor Starting Characteristics of Star-Delta Starter
            • Advantages of Star-Delta starter
            • Disadvantages of Star-Delta starter
            • Features of star-delta starting
            • Application of Star-Delta Starter
            • LESSON 1 WIRING SYSTEM OF SINGLE PHASE DISTRIBUTION BOARD
            • LESSON 2 WIRING SYSTEM OF SINGLE PHASE LIGHTING CIRCUIT
            • LESSON 3ndash WIRING SYSTEM OF SINGLE PHASE POWER CIRCUIT
            • LESSON 4ndash CONDUIT BENDING AND TRUNKING FABRICATION TECHNIQUE
            • LESSON 5 ndashWIRING SYSTEM OF 1 Oslash LIGHTING AND POWER CIRCUIT
              • POWER CIRCUITS
                • LESSON 6 ndash WIRING SYSTEM OF 3 Oslash DISTRIBUTION BOARD
                • LESSON 7 ndash WIRING SYSTEM OF THREE PHASE LIGHTING AND POWER CIRCUIT
                • LESSON 8 INSPECTION AND TESTING OF ELECTRICAL INSTALLATION
                  • CONTINUITY TEST
                    • Polarity Test
                      • Earth Electrode Resistance Test
                      • Earth Electrode Resistance Measurement Method (Figure 86)
                        • Residual Current Device Test
                        • LESSON 9 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (DC)
                        • LESSON 10 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (AC)
                        • LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE
                        • LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
                          • LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
                          • LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
                          • LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
                            • a Dead circuit test
                            • b Life circuit test
                            • LESSON 16
                              • TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
                              • SELF-ASSESSMENT QUESTIONS
Page 7: WorksheetTask AMIN

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

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This is the conductor which is connected between the consumer earthing point and the exposed

metallic part The minimum cable size for this purpose is 10 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

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iv Small metallic parts such as screws and name plates which are isolated by means of insulation

v Metallic lamp parts for filament lamps in water proof floors

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

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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

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Direct contact occurs when the worker or consumer receives an electrical shock on touching directly a

live conductor or cable

b Indirect Contact

Here the electric shock occurs due to contact with a part which is connected to the electrical

installation and not to a direct contact with a live cable or conductor possibly due to damages in the

appliance or insulation resulting in leakages of current

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

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A first aid box has to be provided by the building owner construction site supervisor or brought

personally by the worker under the supervision of the responsible person

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

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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

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3 In operation the Main Contactor (KM3) and the Star Contactor (KM1) are closed initially and

then after a period of time the star contactor is opened and then the delta contactor (KM2) is

closed The control of the contactors is by the timer (K1T) built into the starter The Star and Delta

are electrically interlocked and preferably mechanically interlocked as well In effect there are

four states

4 The star contactor serves to initially short the secondary terminal of the motor U2 V2 W2 for the

start sequence during the initial run of the motor from standstill This provides one third of DOL

current to the motor thus reducing the high inrush current inherent with large capacity motors at

startup

5 Controlling the interchanging star connection and delta connection of an AC induction motor is

achieved by means of a star delta or wye delta control circuit The control circuit consists of push

button switches auxiliary contacts and a timer

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

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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

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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

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Closed Transition State The Main [KM3] contactor is closed and the Delta [KM2] and Star

[KM1] contactors are open Current flows through the motor windings and the transition resistors

via KM4

Delta State The Main and the Delta contactors are closed The transition resistors are shorted out

The Star contactor is open The motor is connected to full line voltage and full power and torque

are available

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

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In the windings means that the overload is placed after the point where the wiring to the contactors

are split into main and delta The overload then always measures the current inside the windings

The setting of Overload Relay (In Winding) =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

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In this method of starting initially motor is connected in star and then after change over the motor

is connected in delta The delta of motor is formed in starter and not on motor terminals

High transmission and current peaks When starting up pumps and fans for example the load

torque is low at the beginning of the start and increases with the square of the speed When

reaching approx 80-85 of the motor rated speed the load torque is equal to the motor torque and

the acceleration ceases To reach the rated speed a switch over to delta position is necessary and

this will very often result in high transmission and current peaks In some cases the current peak

can reach a value that is even bigger than for a 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

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loaded there will not be enough torque to accelerate the motor up to speed before switching over

to the delta position

LESSON 1 WIRING SYSTEM OF SINGLE PHASE DISTRIBUTION BOARD

Introduction

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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

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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

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Objectives

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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

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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

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Objectives

1 Identify conduit fitting and the specification

2 Measure and Cut steel conduit according to specified dimension

3 Bend and fabricate conduit at 45 90 according to layout diagram

4 Wire component according to the schematic diagram

5 Test the functionality of the circuit

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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

  • ELECTRICITY SUPPLY SPECIFICATIONS
    • Legal Requirements
    • Determining Consumer Load Requirements
    • 2 CONTROL AND PROTECTION SYSTEM FOR ELECTRICAL WIRING
    • CABLE SELECTION
      • 32 Factors Related to Cable Current Carrying Capacity
      • Functions and Colour Identification of Non Flexible Cables
        • Conductor Insulation and Types of Wiring
        • Functions and Colour Identification of Non Flexible Cables
        • 3 SELECTION OF WIRING ACCESSORIES
        • EARTHING OF ELECTRICAL INSTALLATIONS
          • 4 SAFETY REQUIREMENTS FOR ELECTRICAL WIRING WORKS IN RESIDENTIAL BUILDINGS
            • Why Electric Shocks Occur
            • INSTALLATION CIRCUITS AND SYSTEMS
            • Working Principal of Star-Delta Starter
            • Star-delta Starter Consists following units
            • Power Circuit of Star Delta Starter
            • Control Circuit of Star-Delta Starter (Open Transition)
            • What is Open or Closed Transition Starting
            • Effect of Transient in Starter (Open Transient starter)
            • Size of each part of Star-Delta starter
            • Motor Starting Characteristics of Star-Delta Starter
            • Advantages of Star-Delta starter
            • Disadvantages of Star-Delta starter
            • Features of star-delta starting
            • Application of Star-Delta Starter
            • LESSON 1 WIRING SYSTEM OF SINGLE PHASE DISTRIBUTION BOARD
            • LESSON 2 WIRING SYSTEM OF SINGLE PHASE LIGHTING CIRCUIT
            • LESSON 3ndash WIRING SYSTEM OF SINGLE PHASE POWER CIRCUIT
            • LESSON 4ndash CONDUIT BENDING AND TRUNKING FABRICATION TECHNIQUE
            • LESSON 5 ndashWIRING SYSTEM OF 1 Oslash LIGHTING AND POWER CIRCUIT
              • POWER CIRCUITS
                • LESSON 6 ndash WIRING SYSTEM OF 3 Oslash DISTRIBUTION BOARD
                • LESSON 7 ndash WIRING SYSTEM OF THREE PHASE LIGHTING AND POWER CIRCUIT
                • LESSON 8 INSPECTION AND TESTING OF ELECTRICAL INSTALLATION
                  • CONTINUITY TEST
                    • Polarity Test
                      • Earth Electrode Resistance Test
                      • Earth Electrode Resistance Measurement Method (Figure 86)
                        • Residual Current Device Test
                        • LESSON 9 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (DC)
                        • LESSON 10 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (AC)
                        • LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE
                        • LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
                          • LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
                          • LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
                          • LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
                            • a Dead circuit test
                            • b Life circuit test
                            • LESSON 16
                              • TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
                              • SELF-ASSESSMENT QUESTIONS
Page 8: WorksheetTask AMIN

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

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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

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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

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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

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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

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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

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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

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Closed Transition State The Main [KM3] contactor is closed and the Delta [KM2] and Star

[KM1] contactors are open Current flows through the motor windings and the transition resistors

via KM4

Delta State The Main and the Delta contactors are closed The transition resistors are shorted out

The Star contactor is open The motor is connected to full line voltage and full power and torque

are available

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

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In the windings means that the overload is placed after the point where the wiring to the contactors

are split into main and delta The overload then always measures the current inside the windings

The setting of Overload Relay (In Winding) =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

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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

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EZTECH ELECTRICAL INSTALLATION GUIDE

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EZTECH ELECTRICAL INSTALLATION GUIDE

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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

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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

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EZTECH ELECTRICAL INSTALLATION GUIDE

Objectives

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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

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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

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EZTECH ELECTRICAL INSTALLATION GUIDE

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EZTECH ELECTRICAL INSTALLATION GUIDE

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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

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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

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EZTECH ELECTRICAL INSTALLATION GUIDE

45 ndash 99EASYTECH ENTERPRISE

EZTECH ELECTRICAL INSTALLATION GUIDE

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EZTECH ELECTRICAL INSTALLATION GUIDE

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EZTECH ELECTRICAL INSTALLATION GUIDE

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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

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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

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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

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EZTECH ELECTRICAL INSTALLATION GUIDE

Autotransformer starter is used to start a 3 phase induction motor that has a rating between 10 to 15 hp

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TOOLS MATERIAL SPECIFICATION QUANTITY

1 Mounting board 600 x 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

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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

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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

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TOOLS MATERIAL SPECIFICATION QUANTITY

1 Mounting board 600 x 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

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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

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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

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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

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APPENDIX 11

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APPENDIX 111

Attachment Reference

httpswwwtlc-directcoukBook621htm

httpwwwstgovmyindexphpms

15 ndash 99EASYTECH ENTERPRISE

  • ELECTRICITY SUPPLY SPECIFICATIONS
    • Legal Requirements
    • Determining Consumer Load Requirements
    • 2 CONTROL AND PROTECTION SYSTEM FOR ELECTRICAL WIRING
    • CABLE SELECTION
      • 32 Factors Related to Cable Current Carrying Capacity
      • Functions and Colour Identification of Non Flexible Cables
        • Conductor Insulation and Types of Wiring
        • Functions and Colour Identification of Non Flexible Cables
        • 3 SELECTION OF WIRING ACCESSORIES
        • EARTHING OF ELECTRICAL INSTALLATIONS
          • 4 SAFETY REQUIREMENTS FOR ELECTRICAL WIRING WORKS IN RESIDENTIAL BUILDINGS
            • Why Electric Shocks Occur
            • INSTALLATION CIRCUITS AND SYSTEMS
            • Working Principal of Star-Delta Starter
            • Star-delta Starter Consists following units
            • Power Circuit of Star Delta Starter
            • Control Circuit of Star-Delta Starter (Open Transition)
            • What is Open or Closed Transition Starting
            • Effect of Transient in Starter (Open Transient starter)
            • Size of each part of Star-Delta starter
            • Motor Starting Characteristics of Star-Delta Starter
            • Advantages of Star-Delta starter
            • Disadvantages of Star-Delta starter
            • Features of star-delta starting
            • Application of Star-Delta Starter
            • LESSON 1 WIRING SYSTEM OF SINGLE PHASE DISTRIBUTION BOARD
            • LESSON 2 WIRING SYSTEM OF SINGLE PHASE LIGHTING CIRCUIT
            • LESSON 3ndash WIRING SYSTEM OF SINGLE PHASE POWER CIRCUIT
            • LESSON 4ndash CONDUIT BENDING AND TRUNKING FABRICATION TECHNIQUE
            • LESSON 5 ndashWIRING SYSTEM OF 1 Oslash LIGHTING AND POWER CIRCUIT
              • POWER CIRCUITS
                • LESSON 6 ndash WIRING SYSTEM OF 3 Oslash DISTRIBUTION BOARD
                • LESSON 7 ndash WIRING SYSTEM OF THREE PHASE LIGHTING AND POWER CIRCUIT
                • LESSON 8 INSPECTION AND TESTING OF ELECTRICAL INSTALLATION
                  • CONTINUITY TEST
                    • Polarity Test
                      • Earth Electrode Resistance Test
                      • Earth Electrode Resistance Measurement Method (Figure 86)
                        • Residual Current Device Test
                        • LESSON 9 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (DC)
                        • LESSON 10 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (AC)
                        • LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE
                        • LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
                          • LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
                          • LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
                          • LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
                            • a Dead circuit test
                            • b Life circuit test
                            • LESSON 16
                              • TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
                              • SELF-ASSESSMENT QUESTIONS
Page 9: WorksheetTask AMIN

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

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The circuit breakers or fuses must be installed on the live conductors only For three phase circuits all

the circuit breakers or fuses must be combined in one set of circuits

Selection of over current devices must be based on the short circuit fault current levels of the circuit

breaker or main switch (kA)

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

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iii The selected cable must be capable of delivering the electrical energy efficiently

iv The cable size allows it to carry the current without heating the cable

v The voltage drop must not exceed 4 of the supply voltage Refer to Table 4D1B in Appendix III

vi The cable insulation must be suitable for the surrounding conditions of the installation such as the

ability to withstand the surrounding temperatures and the ability to provide mechanical protection

vii Each conductor in the installation must be protected from overcurrent by means of overcurrent

protection devices needed to prevent damage to the cable insulation

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

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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

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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 -

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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

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The motor starter shall be of Direct-On-Line type with the appliance together with the contactor

overload relay and on-off control The circuit 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

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This is the conductor which is connected between the consumer earthing point and the exposed

metallic part The minimum cable size for this purpose is 10 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

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iv Small metallic parts such as screws and name plates which are isolated by means of insulation

v Metallic lamp parts for filament lamps in water proof floors

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

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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

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Direct contact occurs when the worker or consumer receives an electrical shock on touching directly a

live conductor or cable

b Indirect Contact

Here the electric shock occurs due to contact with a part which is connected to the electrical

installation and not to a direct contact with a live cable or conductor possibly due to damages in the

appliance or insulation resulting in leakages of current

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

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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

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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

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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

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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

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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

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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

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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

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EZTECH ELECTRICAL INSTALLATION GUIDE

29 ndash 99EASYTECH ENTERPRISE

EZTECH ELECTRICAL INSTALLATION GUIDE

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EZTECH ELECTRICAL INSTALLATION GUIDE

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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

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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

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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

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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

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EZTECH ELECTRICAL INSTALLATION GUIDE

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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

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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

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EZTECH ELECTRICAL INSTALLATION GUIDE

APPENDIX 111

Attachment Reference

httpswwwtlc-directcoukBook621htm

httpwwwstgovmyindexphpms

15 ndash 99EASYTECH ENTERPRISE

  • ELECTRICITY SUPPLY SPECIFICATIONS
    • Legal Requirements
    • Determining Consumer Load Requirements
    • 2 CONTROL AND PROTECTION SYSTEM FOR ELECTRICAL WIRING
    • CABLE SELECTION
      • 32 Factors Related to Cable Current Carrying Capacity
      • Functions and Colour Identification of Non Flexible Cables
        • Conductor Insulation and Types of Wiring
        • Functions and Colour Identification of Non Flexible Cables
        • 3 SELECTION OF WIRING ACCESSORIES
        • EARTHING OF ELECTRICAL INSTALLATIONS
          • 4 SAFETY REQUIREMENTS FOR ELECTRICAL WIRING WORKS IN RESIDENTIAL BUILDINGS
            • Why Electric Shocks Occur
            • INSTALLATION CIRCUITS AND SYSTEMS
            • Working Principal of Star-Delta Starter
            • Star-delta Starter Consists following units
            • Power Circuit of Star Delta Starter
            • Control Circuit of Star-Delta Starter (Open Transition)
            • What is Open or Closed Transition Starting
            • Effect of Transient in Starter (Open Transient starter)
            • Size of each part of Star-Delta starter
            • Motor Starting Characteristics of Star-Delta Starter
            • Advantages of Star-Delta starter
            • Disadvantages of Star-Delta starter
            • Features of star-delta starting
            • Application of Star-Delta Starter
            • LESSON 1 WIRING SYSTEM OF SINGLE PHASE DISTRIBUTION BOARD
            • LESSON 2 WIRING SYSTEM OF SINGLE PHASE LIGHTING CIRCUIT
            • LESSON 3ndash WIRING SYSTEM OF SINGLE PHASE POWER CIRCUIT
            • LESSON 4ndash CONDUIT BENDING AND TRUNKING FABRICATION TECHNIQUE
            • LESSON 5 ndashWIRING SYSTEM OF 1 Oslash LIGHTING AND POWER CIRCUIT
              • POWER CIRCUITS
                • LESSON 6 ndash WIRING SYSTEM OF 3 Oslash DISTRIBUTION BOARD
                • LESSON 7 ndash WIRING SYSTEM OF THREE PHASE LIGHTING AND POWER CIRCUIT
                • LESSON 8 INSPECTION AND TESTING OF ELECTRICAL INSTALLATION
                  • CONTINUITY TEST
                    • Polarity Test
                      • Earth Electrode Resistance Test
                      • Earth Electrode Resistance Measurement Method (Figure 86)
                        • Residual Current Device Test
                        • LESSON 9 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (DC)
                        • LESSON 10 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (AC)
                        • LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE
                        • LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
                          • LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
                          • LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
                          • LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
                            • a Dead circuit test
                            • b Life circuit test
                            • LESSON 16
                              • TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
                              • SELF-ASSESSMENT QUESTIONS
Page 10: WorksheetTask AMIN

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

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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 -

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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

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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

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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

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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

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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

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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

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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

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EZTECH ELECTRICAL INSTALLATION GUIDE

29 ndash 99EASYTECH ENTERPRISE

EZTECH ELECTRICAL INSTALLATION GUIDE

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EZTECH ELECTRICAL INSTALLATION GUIDE

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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

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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

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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

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EZTECH ELECTRICAL INSTALLATION GUIDE

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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)

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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

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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

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EZTECH ELECTRICAL INSTALLATION GUIDE

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EZTECH ELECTRICAL INSTALLATION GUIDE

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EZTECH ELECTRICAL INSTALLATION GUIDE

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EZTECH ELECTRICAL INSTALLATION GUIDE

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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

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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

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EZTECH ELECTRICAL INSTALLATION GUIDE

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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

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61 ndash 99EASYTECH ENTERPRISE

EZTECH ELECTRICAL INSTALLATION GUIDE

Insulation resitance test

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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

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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

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Polarity test

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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

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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

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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

  • ELECTRICITY SUPPLY SPECIFICATIONS
    • Legal Requirements
    • Determining Consumer Load Requirements
    • 2 CONTROL AND PROTECTION SYSTEM FOR ELECTRICAL WIRING
    • CABLE SELECTION
      • 32 Factors Related to Cable Current Carrying Capacity
      • Functions and Colour Identification of Non Flexible Cables
        • Conductor Insulation and Types of Wiring
        • Functions and Colour Identification of Non Flexible Cables
        • 3 SELECTION OF WIRING ACCESSORIES
        • EARTHING OF ELECTRICAL INSTALLATIONS
          • 4 SAFETY REQUIREMENTS FOR ELECTRICAL WIRING WORKS IN RESIDENTIAL BUILDINGS
            • Why Electric Shocks Occur
            • INSTALLATION CIRCUITS AND SYSTEMS
            • Working Principal of Star-Delta Starter
            • Star-delta Starter Consists following units
            • Power Circuit of Star Delta Starter
            • Control Circuit of Star-Delta Starter (Open Transition)
            • What is Open or Closed Transition Starting
            • Effect of Transient in Starter (Open Transient starter)
            • Size of each part of Star-Delta starter
            • Motor Starting Characteristics of Star-Delta Starter
            • Advantages of Star-Delta starter
            • Disadvantages of Star-Delta starter
            • Features of star-delta starting
            • Application of Star-Delta Starter
            • LESSON 1 WIRING SYSTEM OF SINGLE PHASE DISTRIBUTION BOARD
            • LESSON 2 WIRING SYSTEM OF SINGLE PHASE LIGHTING CIRCUIT
            • LESSON 3ndash WIRING SYSTEM OF SINGLE PHASE POWER CIRCUIT
            • LESSON 4ndash CONDUIT BENDING AND TRUNKING FABRICATION TECHNIQUE
            • LESSON 5 ndashWIRING SYSTEM OF 1 Oslash LIGHTING AND POWER CIRCUIT
              • POWER CIRCUITS
                • LESSON 6 ndash WIRING SYSTEM OF 3 Oslash DISTRIBUTION BOARD
                • LESSON 7 ndash WIRING SYSTEM OF THREE PHASE LIGHTING AND POWER CIRCUIT
                • LESSON 8 INSPECTION AND TESTING OF ELECTRICAL INSTALLATION
                  • CONTINUITY TEST
                    • Polarity Test
                      • Earth Electrode Resistance Test
                      • Earth Electrode Resistance Measurement Method (Figure 86)
                        • Residual Current Device Test
                        • LESSON 9 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (DC)
                        • LESSON 10 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (AC)
                        • LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE
                        • LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
                          • LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
                          • LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
                          • LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
                            • a Dead circuit test
                            • b Life circuit test
                            • LESSON 16
                              • TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
                              • SELF-ASSESSMENT QUESTIONS
Page 11: WorksheetTask AMIN

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

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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

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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 -

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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

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The motor starter shall be of Direct-On-Line type with the appliance together with the contactor

overload relay and on-off control The circuit 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

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This is the conductor which is connected between the consumer earthing point and the exposed

metallic part The minimum cable size for this purpose is 10 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

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iv Small metallic parts such as screws and name plates which are isolated by means of insulation

v Metallic lamp parts for filament lamps in water proof floors

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

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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

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Direct contact occurs when the worker or consumer receives an electrical shock on touching directly a

live conductor or cable

b Indirect Contact

Here the electric shock occurs due to contact with a part which is connected to the electrical

installation and not to a direct contact with a live cable or conductor possibly due to damages in the

appliance or insulation resulting in leakages of current

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

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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

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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

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3 In operation the Main Contactor (KM3) and the Star Contactor (KM1) are closed initially and

then after a period of time the star contactor is opened and then the delta contactor (KM2) is

closed The control of the contactors is by the timer (K1T) built into the starter The Star and Delta

are electrically interlocked and preferably mechanically interlocked as well In effect there are

four states

4 The star contactor serves to initially short the secondary terminal of the motor U2 V2 W2 for the

start sequence during the initial run of the motor from standstill This provides one third of DOL

current to the motor thus reducing the high inrush current inherent with large capacity motors at

startup

5 Controlling the interchanging star connection and delta connection of an AC induction motor is

achieved by means of a star delta or wye delta control circuit The control circuit consists of push

button switches auxiliary contacts and a timer

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

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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

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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

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Closed Transition State The Main [KM3] contactor is closed and the Delta [KM2] and Star

[KM1] contactors are open Current flows through the motor windings and the transition resistors

via KM4

Delta State The Main and the Delta contactors are closed The transition resistors are shorted out

The Star contactor is open The motor is connected to full line voltage and full power and torque

are available

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

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In the windings means that the overload is placed after the point where the wiring to the contactors

are split into main and delta The overload then always measures the current inside the windings

The setting of Overload Relay (In Winding) =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

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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

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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

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EZTECH ELECTRICAL INSTALLATION GUIDE

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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

  • ELECTRICITY SUPPLY SPECIFICATIONS
    • Legal Requirements
    • Determining Consumer Load Requirements
    • 2 CONTROL AND PROTECTION SYSTEM FOR ELECTRICAL WIRING
    • CABLE SELECTION
      • 32 Factors Related to Cable Current Carrying Capacity
      • Functions and Colour Identification of Non Flexible Cables
        • Conductor Insulation and Types of Wiring
        • Functions and Colour Identification of Non Flexible Cables
        • 3 SELECTION OF WIRING ACCESSORIES
        • EARTHING OF ELECTRICAL INSTALLATIONS
          • 4 SAFETY REQUIREMENTS FOR ELECTRICAL WIRING WORKS IN RESIDENTIAL BUILDINGS
            • Why Electric Shocks Occur
            • INSTALLATION CIRCUITS AND SYSTEMS
            • Working Principal of Star-Delta Starter
            • Star-delta Starter Consists following units
            • Power Circuit of Star Delta Starter
            • Control Circuit of Star-Delta Starter (Open Transition)
            • What is Open or Closed Transition Starting
            • Effect of Transient in Starter (Open Transient starter)
            • Size of each part of Star-Delta starter
            • Motor Starting Characteristics of Star-Delta Starter
            • Advantages of Star-Delta starter
            • Disadvantages of Star-Delta starter
            • Features of star-delta starting
            • Application of Star-Delta Starter
            • LESSON 1 WIRING SYSTEM OF SINGLE PHASE DISTRIBUTION BOARD
            • LESSON 2 WIRING SYSTEM OF SINGLE PHASE LIGHTING CIRCUIT
            • LESSON 3ndash WIRING SYSTEM OF SINGLE PHASE POWER CIRCUIT
            • LESSON 4ndash CONDUIT BENDING AND TRUNKING FABRICATION TECHNIQUE
            • LESSON 5 ndashWIRING SYSTEM OF 1 Oslash LIGHTING AND POWER CIRCUIT
              • POWER CIRCUITS
                • LESSON 6 ndash WIRING SYSTEM OF 3 Oslash DISTRIBUTION BOARD
                • LESSON 7 ndash WIRING SYSTEM OF THREE PHASE LIGHTING AND POWER CIRCUIT
                • LESSON 8 INSPECTION AND TESTING OF ELECTRICAL INSTALLATION
                  • CONTINUITY TEST
                    • Polarity Test
                      • Earth Electrode Resistance Test
                      • Earth Electrode Resistance Measurement Method (Figure 86)
                        • Residual Current Device Test
                        • LESSON 9 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (DC)
                        • LESSON 10 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (AC)
                        • LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE
                        • LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
                          • LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
                          • LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
                          • LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
                            • a Dead circuit test
                            • b Life circuit test
                            • LESSON 16
                              • TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
                              • SELF-ASSESSMENT QUESTIONS
Page 12: WorksheetTask AMIN

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

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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

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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

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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

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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

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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

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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

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Closed Transition State The Main [KM3] contactor is closed and the Delta [KM2] and Star

[KM1] contactors are open Current flows through the motor windings and the transition resistors

via KM4

Delta State The Main and the Delta contactors are closed The transition resistors are shorted out

The Star contactor is open The motor is connected to full line voltage and full power and torque

are available

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

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In the windings means that the overload is placed after the point where the wiring to the contactors

are split into main and delta The overload then always measures the current inside the windings

The setting of Overload Relay (In Winding) =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

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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

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EZTECH ELECTRICAL INSTALLATION GUIDE

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EZTECH ELECTRICAL INSTALLATION GUIDE

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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

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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

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EZTECH ELECTRICAL INSTALLATION GUIDE

Objectives

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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

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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

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EZTECH ELECTRICAL INSTALLATION GUIDE

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EZTECH ELECTRICAL INSTALLATION GUIDE

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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

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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

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EZTECH ELECTRICAL INSTALLATION GUIDE

45 ndash 99EASYTECH ENTERPRISE

EZTECH ELECTRICAL INSTALLATION GUIDE

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EZTECH ELECTRICAL INSTALLATION GUIDE

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EZTECH ELECTRICAL INSTALLATION GUIDE

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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

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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

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EZTECH ELECTRICAL INSTALLATION GUIDE

Autotransformer starter is used to start a 3 phase induction motor that has a rating between 10 to 15 hp

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EZTECH ELECTRICAL INSTALLATION GUIDE

TOOLS MATERIAL SPECIFICATION QUANTITY

1 Mounting board 600 x 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

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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

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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

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EZTECH ELECTRICAL INSTALLATION GUIDE

TOOLS MATERIAL SPECIFICATION QUANTITY

1 Mounting board 600 x 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

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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

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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

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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

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EZTECH ELECTRICAL INSTALLATION GUIDE

APPENDIX 111

Attachment Reference

httpswwwtlc-directcoukBook621htm

httpwwwstgovmyindexphpms

15 ndash 99EASYTECH ENTERPRISE

  • ELECTRICITY SUPPLY SPECIFICATIONS
    • Legal Requirements
    • Determining Consumer Load Requirements
    • 2 CONTROL AND PROTECTION SYSTEM FOR ELECTRICAL WIRING
    • CABLE SELECTION
      • 32 Factors Related to Cable Current Carrying Capacity
      • Functions and Colour Identification of Non Flexible Cables
        • Conductor Insulation and Types of Wiring
        • Functions and Colour Identification of Non Flexible Cables
        • 3 SELECTION OF WIRING ACCESSORIES
        • EARTHING OF ELECTRICAL INSTALLATIONS
          • 4 SAFETY REQUIREMENTS FOR ELECTRICAL WIRING WORKS IN RESIDENTIAL BUILDINGS
            • Why Electric Shocks Occur
            • INSTALLATION CIRCUITS AND SYSTEMS
            • Working Principal of Star-Delta Starter
            • Star-delta Starter Consists following units
            • Power Circuit of Star Delta Starter
            • Control Circuit of Star-Delta Starter (Open Transition)
            • What is Open or Closed Transition Starting
            • Effect of Transient in Starter (Open Transient starter)
            • Size of each part of Star-Delta starter
            • Motor Starting Characteristics of Star-Delta Starter
            • Advantages of Star-Delta starter
            • Disadvantages of Star-Delta starter
            • Features of star-delta starting
            • Application of Star-Delta Starter
            • LESSON 1 WIRING SYSTEM OF SINGLE PHASE DISTRIBUTION BOARD
            • LESSON 2 WIRING SYSTEM OF SINGLE PHASE LIGHTING CIRCUIT
            • LESSON 3ndash WIRING SYSTEM OF SINGLE PHASE POWER CIRCUIT
            • LESSON 4ndash CONDUIT BENDING AND TRUNKING FABRICATION TECHNIQUE
            • LESSON 5 ndashWIRING SYSTEM OF 1 Oslash LIGHTING AND POWER CIRCUIT
              • POWER CIRCUITS
                • LESSON 6 ndash WIRING SYSTEM OF 3 Oslash DISTRIBUTION BOARD
                • LESSON 7 ndash WIRING SYSTEM OF THREE PHASE LIGHTING AND POWER CIRCUIT
                • LESSON 8 INSPECTION AND TESTING OF ELECTRICAL INSTALLATION
                  • CONTINUITY TEST
                    • Polarity Test
                      • Earth Electrode Resistance Test
                      • Earth Electrode Resistance Measurement Method (Figure 86)
                        • Residual Current Device Test
                        • LESSON 9 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (DC)
                        • LESSON 10 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (AC)
                        • LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE
                        • LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
                          • LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
                          • LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
                          • LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
                            • a Dead circuit test
                            • b Life circuit test
                            • LESSON 16
                              • TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
                              • SELF-ASSESSMENT QUESTIONS
Page 13: WorksheetTask AMIN

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 -

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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

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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

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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

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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

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Direct contact occurs when the worker or consumer receives an electrical shock on touching directly a

live conductor or cable

b Indirect Contact

Here the electric shock occurs due to contact with a part which is connected to the electrical

installation and not to a direct contact with a live cable or conductor possibly due to damages in the

appliance or insulation resulting in leakages of current

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

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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

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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

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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

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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

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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

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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

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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

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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

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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

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EZTECH ELECTRICAL INSTALLATION GUIDE

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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

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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

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EZTECH ELECTRICAL INSTALLATION GUIDE

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EZTECH ELECTRICAL INSTALLATION GUIDE

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EZTECH ELECTRICAL INSTALLATION GUIDE

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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

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EZTECH ELECTRICAL INSTALLATION GUIDE

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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

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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

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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

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Polarity test

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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

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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

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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

  • ELECTRICITY SUPPLY SPECIFICATIONS
    • Legal Requirements
    • Determining Consumer Load Requirements
    • 2 CONTROL AND PROTECTION SYSTEM FOR ELECTRICAL WIRING
    • CABLE SELECTION
      • 32 Factors Related to Cable Current Carrying Capacity
      • Functions and Colour Identification of Non Flexible Cables
        • Conductor Insulation and Types of Wiring
        • Functions and Colour Identification of Non Flexible Cables
        • 3 SELECTION OF WIRING ACCESSORIES
        • EARTHING OF ELECTRICAL INSTALLATIONS
          • 4 SAFETY REQUIREMENTS FOR ELECTRICAL WIRING WORKS IN RESIDENTIAL BUILDINGS
            • Why Electric Shocks Occur
            • INSTALLATION CIRCUITS AND SYSTEMS
            • Working Principal of Star-Delta Starter
            • Star-delta Starter Consists following units
            • Power Circuit of Star Delta Starter
            • Control Circuit of Star-Delta Starter (Open Transition)
            • What is Open or Closed Transition Starting
            • Effect of Transient in Starter (Open Transient starter)
            • Size of each part of Star-Delta starter
            • Motor Starting Characteristics of Star-Delta Starter
            • Advantages of Star-Delta starter
            • Disadvantages of Star-Delta starter
            • Features of star-delta starting
            • Application of Star-Delta Starter
            • LESSON 1 WIRING SYSTEM OF SINGLE PHASE DISTRIBUTION BOARD
            • LESSON 2 WIRING SYSTEM OF SINGLE PHASE LIGHTING CIRCUIT
            • LESSON 3ndash WIRING SYSTEM OF SINGLE PHASE POWER CIRCUIT
            • LESSON 4ndash CONDUIT BENDING AND TRUNKING FABRICATION TECHNIQUE
            • LESSON 5 ndashWIRING SYSTEM OF 1 Oslash LIGHTING AND POWER CIRCUIT
              • POWER CIRCUITS
                • LESSON 6 ndash WIRING SYSTEM OF 3 Oslash DISTRIBUTION BOARD
                • LESSON 7 ndash WIRING SYSTEM OF THREE PHASE LIGHTING AND POWER CIRCUIT
                • LESSON 8 INSPECTION AND TESTING OF ELECTRICAL INSTALLATION
                  • CONTINUITY TEST
                    • Polarity Test
                      • Earth Electrode Resistance Test
                      • Earth Electrode Resistance Measurement Method (Figure 86)
                        • Residual Current Device Test
                        • LESSON 9 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (DC)
                        • LESSON 10 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (AC)
                        • LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE
                        • LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
                          • LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
                          • LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
                          • LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
                            • a Dead circuit test
                            • b Life circuit test
                            • LESSON 16
                              • TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
                              • SELF-ASSESSMENT QUESTIONS
Page 14: WorksheetTask AMIN

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

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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

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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

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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

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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

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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

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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

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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

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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

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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

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In the windings means that the overload is placed after the point where the wiring to the contactors

are split into main and delta The overload then always measures the current inside the windings

The setting of Overload Relay (In Winding) =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

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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

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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

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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

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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

  • ELECTRICITY SUPPLY SPECIFICATIONS
    • Legal Requirements
    • Determining Consumer Load Requirements
    • 2 CONTROL AND PROTECTION SYSTEM FOR ELECTRICAL WIRING
    • CABLE SELECTION
      • 32 Factors Related to Cable Current Carrying Capacity
      • Functions and Colour Identification of Non Flexible Cables
        • Conductor Insulation and Types of Wiring
        • Functions and Colour Identification of Non Flexible Cables
        • 3 SELECTION OF WIRING ACCESSORIES
        • EARTHING OF ELECTRICAL INSTALLATIONS
          • 4 SAFETY REQUIREMENTS FOR ELECTRICAL WIRING WORKS IN RESIDENTIAL BUILDINGS
            • Why Electric Shocks Occur
            • INSTALLATION CIRCUITS AND SYSTEMS
            • Working Principal of Star-Delta Starter
            • Star-delta Starter Consists following units
            • Power Circuit of Star Delta Starter
            • Control Circuit of Star-Delta Starter (Open Transition)
            • What is Open or Closed Transition Starting
            • Effect of Transient in Starter (Open Transient starter)
            • Size of each part of Star-Delta starter
            • Motor Starting Characteristics of Star-Delta Starter
            • Advantages of Star-Delta starter
            • Disadvantages of Star-Delta starter
            • Features of star-delta starting
            • Application of Star-Delta Starter
            • LESSON 1 WIRING SYSTEM OF SINGLE PHASE DISTRIBUTION BOARD
            • LESSON 2 WIRING SYSTEM OF SINGLE PHASE LIGHTING CIRCUIT
            • LESSON 3ndash WIRING SYSTEM OF SINGLE PHASE POWER CIRCUIT
            • LESSON 4ndash CONDUIT BENDING AND TRUNKING FABRICATION TECHNIQUE
            • LESSON 5 ndashWIRING SYSTEM OF 1 Oslash LIGHTING AND POWER CIRCUIT
              • POWER CIRCUITS
                • LESSON 6 ndash WIRING SYSTEM OF 3 Oslash DISTRIBUTION BOARD
                • LESSON 7 ndash WIRING SYSTEM OF THREE PHASE LIGHTING AND POWER CIRCUIT
                • LESSON 8 INSPECTION AND TESTING OF ELECTRICAL INSTALLATION
                  • CONTINUITY TEST
                    • Polarity Test
                      • Earth Electrode Resistance Test
                      • Earth Electrode Resistance Measurement Method (Figure 86)
                        • Residual Current Device Test
                        • LESSON 9 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (DC)
                        • LESSON 10 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (AC)
                        • LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE
                        • LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
                          • LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
                          • LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
                          • LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
                            • a Dead circuit test
                            • b Life circuit test
                            • LESSON 16
                              • TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
                              • SELF-ASSESSMENT QUESTIONS
Page 15: WorksheetTask AMIN

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

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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

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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

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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

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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

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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

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EZTECH ELECTRICAL INSTALLATION GUIDE

29 ndash 99EASYTECH ENTERPRISE

EZTECH ELECTRICAL INSTALLATION GUIDE

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EZTECH ELECTRICAL INSTALLATION GUIDE

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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

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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

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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

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EZTECH ELECTRICAL INSTALLATION GUIDE

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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

  • ELECTRICITY SUPPLY SPECIFICATIONS
    • Legal Requirements
    • Determining Consumer Load Requirements
    • 2 CONTROL AND PROTECTION SYSTEM FOR ELECTRICAL WIRING
    • CABLE SELECTION
      • 32 Factors Related to Cable Current Carrying Capacity
      • Functions and Colour Identification of Non Flexible Cables
        • Conductor Insulation and Types of Wiring
        • Functions and Colour Identification of Non Flexible Cables
        • 3 SELECTION OF WIRING ACCESSORIES
        • EARTHING OF ELECTRICAL INSTALLATIONS
          • 4 SAFETY REQUIREMENTS FOR ELECTRICAL WIRING WORKS IN RESIDENTIAL BUILDINGS
            • Why Electric Shocks Occur
            • INSTALLATION CIRCUITS AND SYSTEMS
            • Working Principal of Star-Delta Starter
            • Star-delta Starter Consists following units
            • Power Circuit of Star Delta Starter
            • Control Circuit of Star-Delta Starter (Open Transition)
            • What is Open or Closed Transition Starting
            • Effect of Transient in Starter (Open Transient starter)
            • Size of each part of Star-Delta starter
            • Motor Starting Characteristics of Star-Delta Starter
            • Advantages of Star-Delta starter
            • Disadvantages of Star-Delta starter
            • Features of star-delta starting
            • Application of Star-Delta Starter
            • LESSON 1 WIRING SYSTEM OF SINGLE PHASE DISTRIBUTION BOARD
            • LESSON 2 WIRING SYSTEM OF SINGLE PHASE LIGHTING CIRCUIT
            • LESSON 3ndash WIRING SYSTEM OF SINGLE PHASE POWER CIRCUIT
            • LESSON 4ndash CONDUIT BENDING AND TRUNKING FABRICATION TECHNIQUE
            • LESSON 5 ndashWIRING SYSTEM OF 1 Oslash LIGHTING AND POWER CIRCUIT
              • POWER CIRCUITS
                • LESSON 6 ndash WIRING SYSTEM OF 3 Oslash DISTRIBUTION BOARD
                • LESSON 7 ndash WIRING SYSTEM OF THREE PHASE LIGHTING AND POWER CIRCUIT
                • LESSON 8 INSPECTION AND TESTING OF ELECTRICAL INSTALLATION
                  • CONTINUITY TEST
                    • Polarity Test
                      • Earth Electrode Resistance Test
                      • Earth Electrode Resistance Measurement Method (Figure 86)
                        • Residual Current Device Test
                        • LESSON 9 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (DC)
                        • LESSON 10 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (AC)
                        • LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE
                        • LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
                          • LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
                          • LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
                          • LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
                            • a Dead circuit test
                            • b Life circuit test
                            • LESSON 16
                              • TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
                              • SELF-ASSESSMENT QUESTIONS
Page 16: WorksheetTask AMIN

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

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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

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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

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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

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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

  • ELECTRICITY SUPPLY SPECIFICATIONS
    • Legal Requirements
    • Determining Consumer Load Requirements
    • 2 CONTROL AND PROTECTION SYSTEM FOR ELECTRICAL WIRING
    • CABLE SELECTION
      • 32 Factors Related to Cable Current Carrying Capacity
      • Functions and Colour Identification of Non Flexible Cables
        • Conductor Insulation and Types of Wiring
        • Functions and Colour Identification of Non Flexible Cables
        • 3 SELECTION OF WIRING ACCESSORIES
        • EARTHING OF ELECTRICAL INSTALLATIONS
          • 4 SAFETY REQUIREMENTS FOR ELECTRICAL WIRING WORKS IN RESIDENTIAL BUILDINGS
            • Why Electric Shocks Occur
            • INSTALLATION CIRCUITS AND SYSTEMS
            • Working Principal of Star-Delta Starter
            • Star-delta Starter Consists following units
            • Power Circuit of Star Delta Starter
            • Control Circuit of Star-Delta Starter (Open Transition)
            • What is Open or Closed Transition Starting
            • Effect of Transient in Starter (Open Transient starter)
            • Size of each part of Star-Delta starter
            • Motor Starting Characteristics of Star-Delta Starter
            • Advantages of Star-Delta starter
            • Disadvantages of Star-Delta starter
            • Features of star-delta starting
            • Application of Star-Delta Starter
            • LESSON 1 WIRING SYSTEM OF SINGLE PHASE DISTRIBUTION BOARD
            • LESSON 2 WIRING SYSTEM OF SINGLE PHASE LIGHTING CIRCUIT
            • LESSON 3ndash WIRING SYSTEM OF SINGLE PHASE POWER CIRCUIT
            • LESSON 4ndash CONDUIT BENDING AND TRUNKING FABRICATION TECHNIQUE
            • LESSON 5 ndashWIRING SYSTEM OF 1 Oslash LIGHTING AND POWER CIRCUIT
              • POWER CIRCUITS
                • LESSON 6 ndash WIRING SYSTEM OF 3 Oslash DISTRIBUTION BOARD
                • LESSON 7 ndash WIRING SYSTEM OF THREE PHASE LIGHTING AND POWER CIRCUIT
                • LESSON 8 INSPECTION AND TESTING OF ELECTRICAL INSTALLATION
                  • CONTINUITY TEST
                    • Polarity Test
                      • Earth Electrode Resistance Test
                      • Earth Electrode Resistance Measurement Method (Figure 86)
                        • Residual Current Device Test
                        • LESSON 9 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (DC)
                        • LESSON 10 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (AC)
                        • LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE
                        • LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
                          • LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
                          • LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
                          • LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
                            • a Dead circuit test
                            • b Life circuit test
                            • LESSON 16
                              • TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
                              • SELF-ASSESSMENT QUESTIONS
Page 17: WorksheetTask AMIN

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

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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

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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

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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

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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

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EZTECH ELECTRICAL INSTALLATION GUIDE

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EZTECH ELECTRICAL INSTALLATION GUIDE

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EZTECH ELECTRICAL INSTALLATION GUIDE

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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

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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

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EZTECH ELECTRICAL INSTALLATION GUIDE

Objectives

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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

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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

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EZTECH ELECTRICAL INSTALLATION GUIDE

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EZTECH ELECTRICAL INSTALLATION GUIDE

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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

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EZTECH ELECTRICAL INSTALLATION GUIDE

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EZTECH ELECTRICAL INSTALLATION GUIDE

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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

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EZTECH ELECTRICAL INSTALLATION GUIDE

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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

  • ELECTRICITY SUPPLY SPECIFICATIONS
    • Legal Requirements
    • Determining Consumer Load Requirements
    • 2 CONTROL AND PROTECTION SYSTEM FOR ELECTRICAL WIRING
    • CABLE SELECTION
      • 32 Factors Related to Cable Current Carrying Capacity
      • Functions and Colour Identification of Non Flexible Cables
        • Conductor Insulation and Types of Wiring
        • Functions and Colour Identification of Non Flexible Cables
        • 3 SELECTION OF WIRING ACCESSORIES
        • EARTHING OF ELECTRICAL INSTALLATIONS
          • 4 SAFETY REQUIREMENTS FOR ELECTRICAL WIRING WORKS IN RESIDENTIAL BUILDINGS
            • Why Electric Shocks Occur
            • INSTALLATION CIRCUITS AND SYSTEMS
            • Working Principal of Star-Delta Starter
            • Star-delta Starter Consists following units
            • Power Circuit of Star Delta Starter
            • Control Circuit of Star-Delta Starter (Open Transition)
            • What is Open or Closed Transition Starting
            • Effect of Transient in Starter (Open Transient starter)
            • Size of each part of Star-Delta starter
            • Motor Starting Characteristics of Star-Delta Starter
            • Advantages of Star-Delta starter
            • Disadvantages of Star-Delta starter
            • Features of star-delta starting
            • Application of Star-Delta Starter
            • LESSON 1 WIRING SYSTEM OF SINGLE PHASE DISTRIBUTION BOARD
            • LESSON 2 WIRING SYSTEM OF SINGLE PHASE LIGHTING CIRCUIT
            • LESSON 3ndash WIRING SYSTEM OF SINGLE PHASE POWER CIRCUIT
            • LESSON 4ndash CONDUIT BENDING AND TRUNKING FABRICATION TECHNIQUE
            • LESSON 5 ndashWIRING SYSTEM OF 1 Oslash LIGHTING AND POWER CIRCUIT
              • POWER CIRCUITS
                • LESSON 6 ndash WIRING SYSTEM OF 3 Oslash DISTRIBUTION BOARD
                • LESSON 7 ndash WIRING SYSTEM OF THREE PHASE LIGHTING AND POWER CIRCUIT
                • LESSON 8 INSPECTION AND TESTING OF ELECTRICAL INSTALLATION
                  • CONTINUITY TEST
                    • Polarity Test
                      • Earth Electrode Resistance Test
                      • Earth Electrode Resistance Measurement Method (Figure 86)
                        • Residual Current Device Test
                        • LESSON 9 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (DC)
                        • LESSON 10 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (AC)
                        • LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE
                        • LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
                          • LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
                          • LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
                          • LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
                            • a Dead circuit test
                            • b Life circuit test
                            • LESSON 16
                              • TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
                              • SELF-ASSESSMENT QUESTIONS
Page 18: WorksheetTask AMIN

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

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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

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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

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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

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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

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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

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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

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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

  • ELECTRICITY SUPPLY SPECIFICATIONS
    • Legal Requirements
    • Determining Consumer Load Requirements
    • 2 CONTROL AND PROTECTION SYSTEM FOR ELECTRICAL WIRING
    • CABLE SELECTION
      • 32 Factors Related to Cable Current Carrying Capacity
      • Functions and Colour Identification of Non Flexible Cables
        • Conductor Insulation and Types of Wiring
        • Functions and Colour Identification of Non Flexible Cables
        • 3 SELECTION OF WIRING ACCESSORIES
        • EARTHING OF ELECTRICAL INSTALLATIONS
          • 4 SAFETY REQUIREMENTS FOR ELECTRICAL WIRING WORKS IN RESIDENTIAL BUILDINGS
            • Why Electric Shocks Occur
            • INSTALLATION CIRCUITS AND SYSTEMS
            • Working Principal of Star-Delta Starter
            • Star-delta Starter Consists following units
            • Power Circuit of Star Delta Starter
            • Control Circuit of Star-Delta Starter (Open Transition)
            • What is Open or Closed Transition Starting
            • Effect of Transient in Starter (Open Transient starter)
            • Size of each part of Star-Delta starter
            • Motor Starting Characteristics of Star-Delta Starter
            • Advantages of Star-Delta starter
            • Disadvantages of Star-Delta starter
            • Features of star-delta starting
            • Application of Star-Delta Starter
            • LESSON 1 WIRING SYSTEM OF SINGLE PHASE DISTRIBUTION BOARD
            • LESSON 2 WIRING SYSTEM OF SINGLE PHASE LIGHTING CIRCUIT
            • LESSON 3ndash WIRING SYSTEM OF SINGLE PHASE POWER CIRCUIT
            • LESSON 4ndash CONDUIT BENDING AND TRUNKING FABRICATION TECHNIQUE
            • LESSON 5 ndashWIRING SYSTEM OF 1 Oslash LIGHTING AND POWER CIRCUIT
              • POWER CIRCUITS
                • LESSON 6 ndash WIRING SYSTEM OF 3 Oslash DISTRIBUTION BOARD
                • LESSON 7 ndash WIRING SYSTEM OF THREE PHASE LIGHTING AND POWER CIRCUIT
                • LESSON 8 INSPECTION AND TESTING OF ELECTRICAL INSTALLATION
                  • CONTINUITY TEST
                    • Polarity Test
                      • Earth Electrode Resistance Test
                      • Earth Electrode Resistance Measurement Method (Figure 86)
                        • Residual Current Device Test
                        • LESSON 9 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (DC)
                        • LESSON 10 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (AC)
                        • LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE
                        • LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
                          • LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
                          • LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
                          • LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
                            • a Dead circuit test
                            • b Life circuit test
                            • LESSON 16
                              • TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
                              • SELF-ASSESSMENT QUESTIONS
Page 19: WorksheetTask AMIN

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

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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

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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

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EZTECH ELECTRICAL INSTALLATION GUIDE

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EZTECH ELECTRICAL INSTALLATION GUIDE

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EZTECH ELECTRICAL INSTALLATION GUIDE

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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

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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

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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

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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

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EZTECH ELECTRICAL INSTALLATION GUIDE

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EZTECH ELECTRICAL INSTALLATION GUIDE

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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)

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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

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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

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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

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EZTECH ELECTRICAL INSTALLATION GUIDE

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EZTECH ELECTRICAL INSTALLATION GUIDE

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EZTECH ELECTRICAL INSTALLATION GUIDE

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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

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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

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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

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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

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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

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61 ndash 99EASYTECH ENTERPRISE

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Insulation resitance test

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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

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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

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Polarity test

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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

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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

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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

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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

  • ELECTRICITY SUPPLY SPECIFICATIONS
    • Legal Requirements
    • Determining Consumer Load Requirements
    • 2 CONTROL AND PROTECTION SYSTEM FOR ELECTRICAL WIRING
    • CABLE SELECTION
      • 32 Factors Related to Cable Current Carrying Capacity
      • Functions and Colour Identification of Non Flexible Cables
        • Conductor Insulation and Types of Wiring
        • Functions and Colour Identification of Non Flexible Cables
        • 3 SELECTION OF WIRING ACCESSORIES
        • EARTHING OF ELECTRICAL INSTALLATIONS
          • 4 SAFETY REQUIREMENTS FOR ELECTRICAL WIRING WORKS IN RESIDENTIAL BUILDINGS
            • Why Electric Shocks Occur
            • INSTALLATION CIRCUITS AND SYSTEMS
            • Working Principal of Star-Delta Starter
            • Star-delta Starter Consists following units
            • Power Circuit of Star Delta Starter
            • Control Circuit of Star-Delta Starter (Open Transition)
            • What is Open or Closed Transition Starting
            • Effect of Transient in Starter (Open Transient starter)
            • Size of each part of Star-Delta starter
            • Motor Starting Characteristics of Star-Delta Starter
            • Advantages of Star-Delta starter
            • Disadvantages of Star-Delta starter
            • Features of star-delta starting
            • Application of Star-Delta Starter
            • LESSON 1 WIRING SYSTEM OF SINGLE PHASE DISTRIBUTION BOARD
            • LESSON 2 WIRING SYSTEM OF SINGLE PHASE LIGHTING CIRCUIT
            • LESSON 3ndash WIRING SYSTEM OF SINGLE PHASE POWER CIRCUIT
            • LESSON 4ndash CONDUIT BENDING AND TRUNKING FABRICATION TECHNIQUE
            • LESSON 5 ndashWIRING SYSTEM OF 1 Oslash LIGHTING AND POWER CIRCUIT
              • POWER CIRCUITS
                • LESSON 6 ndash WIRING SYSTEM OF 3 Oslash DISTRIBUTION BOARD
                • LESSON 7 ndash WIRING SYSTEM OF THREE PHASE LIGHTING AND POWER CIRCUIT
                • LESSON 8 INSPECTION AND TESTING OF ELECTRICAL INSTALLATION
                  • CONTINUITY TEST
                    • Polarity Test
                      • Earth Electrode Resistance Test
                      • Earth Electrode Resistance Measurement Method (Figure 86)
                        • Residual Current Device Test
                        • LESSON 9 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (DC)
                        • LESSON 10 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (AC)
                        • LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE
                        • LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
                          • LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
                          • LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
                          • LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
                            • a Dead circuit test
                            • b Life circuit test
                            • LESSON 16
                              • TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
                              • SELF-ASSESSMENT QUESTIONS
Page 20: WorksheetTask AMIN

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

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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

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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

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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

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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

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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

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EZTECH ELECTRICAL INSTALLATION GUIDE

29 ndash 99EASYTECH ENTERPRISE

EZTECH ELECTRICAL INSTALLATION GUIDE

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EZTECH ELECTRICAL INSTALLATION GUIDE

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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

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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

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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

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EZTECH ELECTRICAL INSTALLATION GUIDE

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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

  • ELECTRICITY SUPPLY SPECIFICATIONS
    • Legal Requirements
    • Determining Consumer Load Requirements
    • 2 CONTROL AND PROTECTION SYSTEM FOR ELECTRICAL WIRING
    • CABLE SELECTION
      • 32 Factors Related to Cable Current Carrying Capacity
      • Functions and Colour Identification of Non Flexible Cables
        • Conductor Insulation and Types of Wiring
        • Functions and Colour Identification of Non Flexible Cables
        • 3 SELECTION OF WIRING ACCESSORIES
        • EARTHING OF ELECTRICAL INSTALLATIONS
          • 4 SAFETY REQUIREMENTS FOR ELECTRICAL WIRING WORKS IN RESIDENTIAL BUILDINGS
            • Why Electric Shocks Occur
            • INSTALLATION CIRCUITS AND SYSTEMS
            • Working Principal of Star-Delta Starter
            • Star-delta Starter Consists following units
            • Power Circuit of Star Delta Starter
            • Control Circuit of Star-Delta Starter (Open Transition)
            • What is Open or Closed Transition Starting
            • Effect of Transient in Starter (Open Transient starter)
            • Size of each part of Star-Delta starter
            • Motor Starting Characteristics of Star-Delta Starter
            • Advantages of Star-Delta starter
            • Disadvantages of Star-Delta starter
            • Features of star-delta starting
            • Application of Star-Delta Starter
            • LESSON 1 WIRING SYSTEM OF SINGLE PHASE DISTRIBUTION BOARD
            • LESSON 2 WIRING SYSTEM OF SINGLE PHASE LIGHTING CIRCUIT
            • LESSON 3ndash WIRING SYSTEM OF SINGLE PHASE POWER CIRCUIT
            • LESSON 4ndash CONDUIT BENDING AND TRUNKING FABRICATION TECHNIQUE
            • LESSON 5 ndashWIRING SYSTEM OF 1 Oslash LIGHTING AND POWER CIRCUIT
              • POWER CIRCUITS
                • LESSON 6 ndash WIRING SYSTEM OF 3 Oslash DISTRIBUTION BOARD
                • LESSON 7 ndash WIRING SYSTEM OF THREE PHASE LIGHTING AND POWER CIRCUIT
                • LESSON 8 INSPECTION AND TESTING OF ELECTRICAL INSTALLATION
                  • CONTINUITY TEST
                    • Polarity Test
                      • Earth Electrode Resistance Test
                      • Earth Electrode Resistance Measurement Method (Figure 86)
                        • Residual Current Device Test
                        • LESSON 9 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (DC)
                        • LESSON 10 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (AC)
                        • LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE
                        • LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
                          • LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
                          • LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
                          • LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
                            • a Dead circuit test
                            • b Life circuit test
                            • LESSON 16
                              • TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
                              • SELF-ASSESSMENT QUESTIONS
Page 21: WorksheetTask AMIN

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

  • ELECTRICITY SUPPLY SPECIFICATIONS
    • Legal Requirements
    • Determining Consumer Load Requirements
    • 2 CONTROL AND PROTECTION SYSTEM FOR ELECTRICAL WIRING
    • CABLE SELECTION
      • 32 Factors Related to Cable Current Carrying Capacity
      • Functions and Colour Identification of Non Flexible Cables
        • Conductor Insulation and Types of Wiring
        • Functions and Colour Identification of Non Flexible Cables
        • 3 SELECTION OF WIRING ACCESSORIES
        • EARTHING OF ELECTRICAL INSTALLATIONS
          • 4 SAFETY REQUIREMENTS FOR ELECTRICAL WIRING WORKS IN RESIDENTIAL BUILDINGS
            • Why Electric Shocks Occur
            • INSTALLATION CIRCUITS AND SYSTEMS
            • Working Principal of Star-Delta Starter
            • Star-delta Starter Consists following units
            • Power Circuit of Star Delta Starter
            • Control Circuit of Star-Delta Starter (Open Transition)
            • What is Open or Closed Transition Starting
            • Effect of Transient in Starter (Open Transient starter)
            • Size of each part of Star-Delta starter
            • Motor Starting Characteristics of Star-Delta Starter
            • Advantages of Star-Delta starter
            • Disadvantages of Star-Delta starter
            • Features of star-delta starting
            • Application of Star-Delta Starter
            • LESSON 1 WIRING SYSTEM OF SINGLE PHASE DISTRIBUTION BOARD
            • LESSON 2 WIRING SYSTEM OF SINGLE PHASE LIGHTING CIRCUIT
            • LESSON 3ndash WIRING SYSTEM OF SINGLE PHASE POWER CIRCUIT
            • LESSON 4ndash CONDUIT BENDING AND TRUNKING FABRICATION TECHNIQUE
            • LESSON 5 ndashWIRING SYSTEM OF 1 Oslash LIGHTING AND POWER CIRCUIT
              • POWER CIRCUITS
                • LESSON 6 ndash WIRING SYSTEM OF 3 Oslash DISTRIBUTION BOARD
                • LESSON 7 ndash WIRING SYSTEM OF THREE PHASE LIGHTING AND POWER CIRCUIT
                • LESSON 8 INSPECTION AND TESTING OF ELECTRICAL INSTALLATION
                  • CONTINUITY TEST
                    • Polarity Test
                      • Earth Electrode Resistance Test
                      • Earth Electrode Resistance Measurement Method (Figure 86)
                        • Residual Current Device Test
                        • LESSON 9 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (DC)
                        • LESSON 10 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (AC)
                        • LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE
                        • LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
                          • LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
                          • LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
                          • LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
                            • a Dead circuit test
                            • b Life circuit test
                            • LESSON 16
                              • TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
                              • SELF-ASSESSMENT QUESTIONS
Page 22: WorksheetTask AMIN

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

  • ELECTRICITY SUPPLY SPECIFICATIONS
    • Legal Requirements
    • Determining Consumer Load Requirements
    • 2 CONTROL AND PROTECTION SYSTEM FOR ELECTRICAL WIRING
    • CABLE SELECTION
      • 32 Factors Related to Cable Current Carrying Capacity
      • Functions and Colour Identification of Non Flexible Cables
        • Conductor Insulation and Types of Wiring
        • Functions and Colour Identification of Non Flexible Cables
        • 3 SELECTION OF WIRING ACCESSORIES
        • EARTHING OF ELECTRICAL INSTALLATIONS
          • 4 SAFETY REQUIREMENTS FOR ELECTRICAL WIRING WORKS IN RESIDENTIAL BUILDINGS
            • Why Electric Shocks Occur
            • INSTALLATION CIRCUITS AND SYSTEMS
            • Working Principal of Star-Delta Starter
            • Star-delta Starter Consists following units
            • Power Circuit of Star Delta Starter
            • Control Circuit of Star-Delta Starter (Open Transition)
            • What is Open or Closed Transition Starting
            • Effect of Transient in Starter (Open Transient starter)
            • Size of each part of Star-Delta starter
            • Motor Starting Characteristics of Star-Delta Starter
            • Advantages of Star-Delta starter
            • Disadvantages of Star-Delta starter
            • Features of star-delta starting
            • Application of Star-Delta Starter
            • LESSON 1 WIRING SYSTEM OF SINGLE PHASE DISTRIBUTION BOARD
            • LESSON 2 WIRING SYSTEM OF SINGLE PHASE LIGHTING CIRCUIT
            • LESSON 3ndash WIRING SYSTEM OF SINGLE PHASE POWER CIRCUIT
            • LESSON 4ndash CONDUIT BENDING AND TRUNKING FABRICATION TECHNIQUE
            • LESSON 5 ndashWIRING SYSTEM OF 1 Oslash LIGHTING AND POWER CIRCUIT
              • POWER CIRCUITS
                • LESSON 6 ndash WIRING SYSTEM OF 3 Oslash DISTRIBUTION BOARD
                • LESSON 7 ndash WIRING SYSTEM OF THREE PHASE LIGHTING AND POWER CIRCUIT
                • LESSON 8 INSPECTION AND TESTING OF ELECTRICAL INSTALLATION
                  • CONTINUITY TEST
                    • Polarity Test
                      • Earth Electrode Resistance Test
                      • Earth Electrode Resistance Measurement Method (Figure 86)
                        • Residual Current Device Test
                        • LESSON 9 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (DC)
                        • LESSON 10 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (AC)
                        • LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE
                        • LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
                          • LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
                          • LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
                          • LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
                            • a Dead circuit test
                            • b Life circuit test
                            • LESSON 16
                              • TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
                              • SELF-ASSESSMENT QUESTIONS
Page 23: WorksheetTask AMIN

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

  • ELECTRICITY SUPPLY SPECIFICATIONS
    • Legal Requirements
    • Determining Consumer Load Requirements
    • 2 CONTROL AND PROTECTION SYSTEM FOR ELECTRICAL WIRING
    • CABLE SELECTION
      • 32 Factors Related to Cable Current Carrying Capacity
      • Functions and Colour Identification of Non Flexible Cables
        • Conductor Insulation and Types of Wiring
        • Functions and Colour Identification of Non Flexible Cables
        • 3 SELECTION OF WIRING ACCESSORIES
        • EARTHING OF ELECTRICAL INSTALLATIONS
          • 4 SAFETY REQUIREMENTS FOR ELECTRICAL WIRING WORKS IN RESIDENTIAL BUILDINGS
            • Why Electric Shocks Occur
            • INSTALLATION CIRCUITS AND SYSTEMS
            • Working Principal of Star-Delta Starter
            • Star-delta Starter Consists following units
            • Power Circuit of Star Delta Starter
            • Control Circuit of Star-Delta Starter (Open Transition)
            • What is Open or Closed Transition Starting
            • Effect of Transient in Starter (Open Transient starter)
            • Size of each part of Star-Delta starter
            • Motor Starting Characteristics of Star-Delta Starter
            • Advantages of Star-Delta starter
            • Disadvantages of Star-Delta starter
            • Features of star-delta starting
            • Application of Star-Delta Starter
            • LESSON 1 WIRING SYSTEM OF SINGLE PHASE DISTRIBUTION BOARD
            • LESSON 2 WIRING SYSTEM OF SINGLE PHASE LIGHTING CIRCUIT
            • LESSON 3ndash WIRING SYSTEM OF SINGLE PHASE POWER CIRCUIT
            • LESSON 4ndash CONDUIT BENDING AND TRUNKING FABRICATION TECHNIQUE
            • LESSON 5 ndashWIRING SYSTEM OF 1 Oslash LIGHTING AND POWER CIRCUIT
              • POWER CIRCUITS
                • LESSON 6 ndash WIRING SYSTEM OF 3 Oslash DISTRIBUTION BOARD
                • LESSON 7 ndash WIRING SYSTEM OF THREE PHASE LIGHTING AND POWER CIRCUIT
                • LESSON 8 INSPECTION AND TESTING OF ELECTRICAL INSTALLATION
                  • CONTINUITY TEST
                    • Polarity Test
                      • Earth Electrode Resistance Test
                      • Earth Electrode Resistance Measurement Method (Figure 86)
                        • Residual Current Device Test
                        • LESSON 9 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (DC)
                        • LESSON 10 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (AC)
                        • LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE
                        • LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
                          • LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
                          • LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
                          • LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
                            • a Dead circuit test
                            • b Life circuit test
                            • LESSON 16
                              • TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
                              • SELF-ASSESSMENT QUESTIONS
Page 24: WorksheetTask AMIN

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

  • ELECTRICITY SUPPLY SPECIFICATIONS
    • Legal Requirements
    • Determining Consumer Load Requirements
    • 2 CONTROL AND PROTECTION SYSTEM FOR ELECTRICAL WIRING
    • CABLE SELECTION
      • 32 Factors Related to Cable Current Carrying Capacity
      • Functions and Colour Identification of Non Flexible Cables
        • Conductor Insulation and Types of Wiring
        • Functions and Colour Identification of Non Flexible Cables
        • 3 SELECTION OF WIRING ACCESSORIES
        • EARTHING OF ELECTRICAL INSTALLATIONS
          • 4 SAFETY REQUIREMENTS FOR ELECTRICAL WIRING WORKS IN RESIDENTIAL BUILDINGS
            • Why Electric Shocks Occur
            • INSTALLATION CIRCUITS AND SYSTEMS
            • Working Principal of Star-Delta Starter
            • Star-delta Starter Consists following units
            • Power Circuit of Star Delta Starter
            • Control Circuit of Star-Delta Starter (Open Transition)
            • What is Open or Closed Transition Starting
            • Effect of Transient in Starter (Open Transient starter)
            • Size of each part of Star-Delta starter
            • Motor Starting Characteristics of Star-Delta Starter
            • Advantages of Star-Delta starter
            • Disadvantages of Star-Delta starter
            • Features of star-delta starting
            • Application of Star-Delta Starter
            • LESSON 1 WIRING SYSTEM OF SINGLE PHASE DISTRIBUTION BOARD
            • LESSON 2 WIRING SYSTEM OF SINGLE PHASE LIGHTING CIRCUIT
            • LESSON 3ndash WIRING SYSTEM OF SINGLE PHASE POWER CIRCUIT
            • LESSON 4ndash CONDUIT BENDING AND TRUNKING FABRICATION TECHNIQUE
            • LESSON 5 ndashWIRING SYSTEM OF 1 Oslash LIGHTING AND POWER CIRCUIT
              • POWER CIRCUITS
                • LESSON 6 ndash WIRING SYSTEM OF 3 Oslash DISTRIBUTION BOARD
                • LESSON 7 ndash WIRING SYSTEM OF THREE PHASE LIGHTING AND POWER CIRCUIT
                • LESSON 8 INSPECTION AND TESTING OF ELECTRICAL INSTALLATION
                  • CONTINUITY TEST
                    • Polarity Test
                      • Earth Electrode Resistance Test
                      • Earth Electrode Resistance Measurement Method (Figure 86)
                        • Residual Current Device Test
                        • LESSON 9 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (DC)
                        • LESSON 10 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (AC)
                        • LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE
                        • LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
                          • LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
                          • LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
                          • LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
                            • a Dead circuit test
                            • b Life circuit test
                            • LESSON 16
                              • TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
                              • SELF-ASSESSMENT QUESTIONS
Page 25: WorksheetTask AMIN

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

  • ELECTRICITY SUPPLY SPECIFICATIONS
    • Legal Requirements
    • Determining Consumer Load Requirements
    • 2 CONTROL AND PROTECTION SYSTEM FOR ELECTRICAL WIRING
    • CABLE SELECTION
      • 32 Factors Related to Cable Current Carrying Capacity
      • Functions and Colour Identification of Non Flexible Cables
        • Conductor Insulation and Types of Wiring
        • Functions and Colour Identification of Non Flexible Cables
        • 3 SELECTION OF WIRING ACCESSORIES
        • EARTHING OF ELECTRICAL INSTALLATIONS
          • 4 SAFETY REQUIREMENTS FOR ELECTRICAL WIRING WORKS IN RESIDENTIAL BUILDINGS
            • Why Electric Shocks Occur
            • INSTALLATION CIRCUITS AND SYSTEMS
            • Working Principal of Star-Delta Starter
            • Star-delta Starter Consists following units
            • Power Circuit of Star Delta Starter
            • Control Circuit of Star-Delta Starter (Open Transition)
            • What is Open or Closed Transition Starting
            • Effect of Transient in Starter (Open Transient starter)
            • Size of each part of Star-Delta starter
            • Motor Starting Characteristics of Star-Delta Starter
            • Advantages of Star-Delta starter
            • Disadvantages of Star-Delta starter
            • Features of star-delta starting
            • Application of Star-Delta Starter
            • LESSON 1 WIRING SYSTEM OF SINGLE PHASE DISTRIBUTION BOARD
            • LESSON 2 WIRING SYSTEM OF SINGLE PHASE LIGHTING CIRCUIT
            • LESSON 3ndash WIRING SYSTEM OF SINGLE PHASE POWER CIRCUIT
            • LESSON 4ndash CONDUIT BENDING AND TRUNKING FABRICATION TECHNIQUE
            • LESSON 5 ndashWIRING SYSTEM OF 1 Oslash LIGHTING AND POWER CIRCUIT
              • POWER CIRCUITS
                • LESSON 6 ndash WIRING SYSTEM OF 3 Oslash DISTRIBUTION BOARD
                • LESSON 7 ndash WIRING SYSTEM OF THREE PHASE LIGHTING AND POWER CIRCUIT
                • LESSON 8 INSPECTION AND TESTING OF ELECTRICAL INSTALLATION
                  • CONTINUITY TEST
                    • Polarity Test
                      • Earth Electrode Resistance Test
                      • Earth Electrode Resistance Measurement Method (Figure 86)
                        • Residual Current Device Test
                        • LESSON 9 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (DC)
                        • LESSON 10 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (AC)
                        • LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE
                        • LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
                          • LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
                          • LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
                          • LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
                            • a Dead circuit test
                            • b Life circuit test
                            • LESSON 16
                              • TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
                              • SELF-ASSESSMENT QUESTIONS
Page 26: WorksheetTask AMIN

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

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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

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EZTECH ELECTRICAL INSTALLATION GUIDE

APPENDIX 111

Attachment Reference

httpswwwtlc-directcoukBook621htm

httpwwwstgovmyindexphpms

15 ndash 99EASYTECH ENTERPRISE

  • ELECTRICITY SUPPLY SPECIFICATIONS
    • Legal Requirements
    • Determining Consumer Load Requirements
    • 2 CONTROL AND PROTECTION SYSTEM FOR ELECTRICAL WIRING
    • CABLE SELECTION
      • 32 Factors Related to Cable Current Carrying Capacity
      • Functions and Colour Identification of Non Flexible Cables
        • Conductor Insulation and Types of Wiring
        • Functions and Colour Identification of Non Flexible Cables
        • 3 SELECTION OF WIRING ACCESSORIES
        • EARTHING OF ELECTRICAL INSTALLATIONS
          • 4 SAFETY REQUIREMENTS FOR ELECTRICAL WIRING WORKS IN RESIDENTIAL BUILDINGS
            • Why Electric Shocks Occur
            • INSTALLATION CIRCUITS AND SYSTEMS
            • Working Principal of Star-Delta Starter
            • Star-delta Starter Consists following units
            • Power Circuit of Star Delta Starter
            • Control Circuit of Star-Delta Starter (Open Transition)
            • What is Open or Closed Transition Starting
            • Effect of Transient in Starter (Open Transient starter)
            • Size of each part of Star-Delta starter
            • Motor Starting Characteristics of Star-Delta Starter
            • Advantages of Star-Delta starter
            • Disadvantages of Star-Delta starter
            • Features of star-delta starting
            • Application of Star-Delta Starter
            • LESSON 1 WIRING SYSTEM OF SINGLE PHASE DISTRIBUTION BOARD
            • LESSON 2 WIRING SYSTEM OF SINGLE PHASE LIGHTING CIRCUIT
            • LESSON 3ndash WIRING SYSTEM OF SINGLE PHASE POWER CIRCUIT
            • LESSON 4ndash CONDUIT BENDING AND TRUNKING FABRICATION TECHNIQUE
            • LESSON 5 ndashWIRING SYSTEM OF 1 Oslash LIGHTING AND POWER CIRCUIT
              • POWER CIRCUITS
                • LESSON 6 ndash WIRING SYSTEM OF 3 Oslash DISTRIBUTION BOARD
                • LESSON 7 ndash WIRING SYSTEM OF THREE PHASE LIGHTING AND POWER CIRCUIT
                • LESSON 8 INSPECTION AND TESTING OF ELECTRICAL INSTALLATION
                  • CONTINUITY TEST
                    • Polarity Test
                      • Earth Electrode Resistance Test
                      • Earth Electrode Resistance Measurement Method (Figure 86)
                        • Residual Current Device Test
                        • LESSON 9 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (DC)
                        • LESSON 10 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (AC)
                        • LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE
                        • LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
                          • LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
                          • LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
                          • LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
                            • a Dead circuit test
                            • b Life circuit test
                            • LESSON 16
                              • TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
                              • SELF-ASSESSMENT QUESTIONS
Page 27: WorksheetTask AMIN

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

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EZTECH ELECTRICAL INSTALLATION GUIDE

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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

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EZTECH ELECTRICAL INSTALLATION GUIDE

Objectives

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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

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EZTECH ELECTRICAL INSTALLATION GUIDE

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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

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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

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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

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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

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EZTECH ELECTRICAL INSTALLATION GUIDE

APPENDIX 11

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EZTECH ELECTRICAL INSTALLATION GUIDE

APPENDIX 111

Attachment Reference

httpswwwtlc-directcoukBook621htm

httpwwwstgovmyindexphpms

15 ndash 99EASYTECH ENTERPRISE

  • ELECTRICITY SUPPLY SPECIFICATIONS
    • Legal Requirements
    • Determining Consumer Load Requirements
    • 2 CONTROL AND PROTECTION SYSTEM FOR ELECTRICAL WIRING
    • CABLE SELECTION
      • 32 Factors Related to Cable Current Carrying Capacity
      • Functions and Colour Identification of Non Flexible Cables
        • Conductor Insulation and Types of Wiring
        • Functions and Colour Identification of Non Flexible Cables
        • 3 SELECTION OF WIRING ACCESSORIES
        • EARTHING OF ELECTRICAL INSTALLATIONS
          • 4 SAFETY REQUIREMENTS FOR ELECTRICAL WIRING WORKS IN RESIDENTIAL BUILDINGS
            • Why Electric Shocks Occur
            • INSTALLATION CIRCUITS AND SYSTEMS
            • Working Principal of Star-Delta Starter
            • Star-delta Starter Consists following units
            • Power Circuit of Star Delta Starter
            • Control Circuit of Star-Delta Starter (Open Transition)
            • What is Open or Closed Transition Starting
            • Effect of Transient in Starter (Open Transient starter)
            • Size of each part of Star-Delta starter
            • Motor Starting Characteristics of Star-Delta Starter
            • Advantages of Star-Delta starter
            • Disadvantages of Star-Delta starter
            • Features of star-delta starting
            • Application of Star-Delta Starter
            • LESSON 1 WIRING SYSTEM OF SINGLE PHASE DISTRIBUTION BOARD
            • LESSON 2 WIRING SYSTEM OF SINGLE PHASE LIGHTING CIRCUIT
            • LESSON 3ndash WIRING SYSTEM OF SINGLE PHASE POWER CIRCUIT
            • LESSON 4ndash CONDUIT BENDING AND TRUNKING FABRICATION TECHNIQUE
            • LESSON 5 ndashWIRING SYSTEM OF 1 Oslash LIGHTING AND POWER CIRCUIT
              • POWER CIRCUITS
                • LESSON 6 ndash WIRING SYSTEM OF 3 Oslash DISTRIBUTION BOARD
                • LESSON 7 ndash WIRING SYSTEM OF THREE PHASE LIGHTING AND POWER CIRCUIT
                • LESSON 8 INSPECTION AND TESTING OF ELECTRICAL INSTALLATION
                  • CONTINUITY TEST
                    • Polarity Test
                      • Earth Electrode Resistance Test
                      • Earth Electrode Resistance Measurement Method (Figure 86)
                        • Residual Current Device Test
                        • LESSON 9 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (DC)
                        • LESSON 10 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (AC)
                        • LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE
                        • LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
                          • LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
                          • LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
                          • LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
                            • a Dead circuit test
                            • b Life circuit test
                            • LESSON 16
                              • TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
                              • SELF-ASSESSMENT QUESTIONS
Page 28: WorksheetTask AMIN

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

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EZTECH ELECTRICAL INSTALLATION GUIDE

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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

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EZTECH ELECTRICAL INSTALLATION GUIDE

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EZTECH ELECTRICAL INSTALLATION GUIDE

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EZTECH ELECTRICAL INSTALLATION GUIDE

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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

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EZTECH ELECTRICAL INSTALLATION GUIDE

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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

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61 ndash 99EASYTECH ENTERPRISE

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Insulation resitance test

62 ndash 99EASYTECH ENTERPRISE

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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

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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

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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

  • ELECTRICITY SUPPLY SPECIFICATIONS
    • Legal Requirements
    • Determining Consumer Load Requirements
    • 2 CONTROL AND PROTECTION SYSTEM FOR ELECTRICAL WIRING
    • CABLE SELECTION
      • 32 Factors Related to Cable Current Carrying Capacity
      • Functions and Colour Identification of Non Flexible Cables
        • Conductor Insulation and Types of Wiring
        • Functions and Colour Identification of Non Flexible Cables
        • 3 SELECTION OF WIRING ACCESSORIES
        • EARTHING OF ELECTRICAL INSTALLATIONS
          • 4 SAFETY REQUIREMENTS FOR ELECTRICAL WIRING WORKS IN RESIDENTIAL BUILDINGS
            • Why Electric Shocks Occur
            • INSTALLATION CIRCUITS AND SYSTEMS
            • Working Principal of Star-Delta Starter
            • Star-delta Starter Consists following units
            • Power Circuit of Star Delta Starter
            • Control Circuit of Star-Delta Starter (Open Transition)
            • What is Open or Closed Transition Starting
            • Effect of Transient in Starter (Open Transient starter)
            • Size of each part of Star-Delta starter
            • Motor Starting Characteristics of Star-Delta Starter
            • Advantages of Star-Delta starter
            • Disadvantages of Star-Delta starter
            • Features of star-delta starting
            • Application of Star-Delta Starter
            • LESSON 1 WIRING SYSTEM OF SINGLE PHASE DISTRIBUTION BOARD
            • LESSON 2 WIRING SYSTEM OF SINGLE PHASE LIGHTING CIRCUIT
            • LESSON 3ndash WIRING SYSTEM OF SINGLE PHASE POWER CIRCUIT
            • LESSON 4ndash CONDUIT BENDING AND TRUNKING FABRICATION TECHNIQUE
            • LESSON 5 ndashWIRING SYSTEM OF 1 Oslash LIGHTING AND POWER CIRCUIT
              • POWER CIRCUITS
                • LESSON 6 ndash WIRING SYSTEM OF 3 Oslash DISTRIBUTION BOARD
                • LESSON 7 ndash WIRING SYSTEM OF THREE PHASE LIGHTING AND POWER CIRCUIT
                • LESSON 8 INSPECTION AND TESTING OF ELECTRICAL INSTALLATION
                  • CONTINUITY TEST
                    • Polarity Test
                      • Earth Electrode Resistance Test
                      • Earth Electrode Resistance Measurement Method (Figure 86)
                        • Residual Current Device Test
                        • LESSON 9 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (DC)
                        • LESSON 10 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (AC)
                        • LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE
                        • LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
                          • LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
                          • LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
                          • LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
                            • a Dead circuit test
                            • b Life circuit test
                            • LESSON 16
                              • TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
                              • SELF-ASSESSMENT QUESTIONS
Page 29: WorksheetTask AMIN

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

  • ELECTRICITY SUPPLY SPECIFICATIONS
    • Legal Requirements
    • Determining Consumer Load Requirements
    • 2 CONTROL AND PROTECTION SYSTEM FOR ELECTRICAL WIRING
    • CABLE SELECTION
      • 32 Factors Related to Cable Current Carrying Capacity
      • Functions and Colour Identification of Non Flexible Cables
        • Conductor Insulation and Types of Wiring
        • Functions and Colour Identification of Non Flexible Cables
        • 3 SELECTION OF WIRING ACCESSORIES
        • EARTHING OF ELECTRICAL INSTALLATIONS
          • 4 SAFETY REQUIREMENTS FOR ELECTRICAL WIRING WORKS IN RESIDENTIAL BUILDINGS
            • Why Electric Shocks Occur
            • INSTALLATION CIRCUITS AND SYSTEMS
            • Working Principal of Star-Delta Starter
            • Star-delta Starter Consists following units
            • Power Circuit of Star Delta Starter
            • Control Circuit of Star-Delta Starter (Open Transition)
            • What is Open or Closed Transition Starting
            • Effect of Transient in Starter (Open Transient starter)
            • Size of each part of Star-Delta starter
            • Motor Starting Characteristics of Star-Delta Starter
            • Advantages of Star-Delta starter
            • Disadvantages of Star-Delta starter
            • Features of star-delta starting
            • Application of Star-Delta Starter
            • LESSON 1 WIRING SYSTEM OF SINGLE PHASE DISTRIBUTION BOARD
            • LESSON 2 WIRING SYSTEM OF SINGLE PHASE LIGHTING CIRCUIT
            • LESSON 3ndash WIRING SYSTEM OF SINGLE PHASE POWER CIRCUIT
            • LESSON 4ndash CONDUIT BENDING AND TRUNKING FABRICATION TECHNIQUE
            • LESSON 5 ndashWIRING SYSTEM OF 1 Oslash LIGHTING AND POWER CIRCUIT
              • POWER CIRCUITS
                • LESSON 6 ndash WIRING SYSTEM OF 3 Oslash DISTRIBUTION BOARD
                • LESSON 7 ndash WIRING SYSTEM OF THREE PHASE LIGHTING AND POWER CIRCUIT
                • LESSON 8 INSPECTION AND TESTING OF ELECTRICAL INSTALLATION
                  • CONTINUITY TEST
                    • Polarity Test
                      • Earth Electrode Resistance Test
                      • Earth Electrode Resistance Measurement Method (Figure 86)
                        • Residual Current Device Test
                        • LESSON 9 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (DC)
                        • LESSON 10 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (AC)
                        • LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE
                        • LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
                          • LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
                          • LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
                          • LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
                            • a Dead circuit test
                            • b Life circuit test
                            • LESSON 16
                              • TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
                              • SELF-ASSESSMENT QUESTIONS
Page 30: WorksheetTask AMIN

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

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EZTECH ELECTRICAL INSTALLATION GUIDE

TOOLS MATERIAL SPECIFICATION QUANTITY

1 Mounting board 600 x 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

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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

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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

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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

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EZTECH ELECTRICAL INSTALLATION GUIDE

APPENDIX 11

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EZTECH ELECTRICAL INSTALLATION GUIDE

APPENDIX 111

Attachment Reference

httpswwwtlc-directcoukBook621htm

httpwwwstgovmyindexphpms

15 ndash 99EASYTECH ENTERPRISE

  • ELECTRICITY SUPPLY SPECIFICATIONS
    • Legal Requirements
    • Determining Consumer Load Requirements
    • 2 CONTROL AND PROTECTION SYSTEM FOR ELECTRICAL WIRING
    • CABLE SELECTION
      • 32 Factors Related to Cable Current Carrying Capacity
      • Functions and Colour Identification of Non Flexible Cables
        • Conductor Insulation and Types of Wiring
        • Functions and Colour Identification of Non Flexible Cables
        • 3 SELECTION OF WIRING ACCESSORIES
        • EARTHING OF ELECTRICAL INSTALLATIONS
          • 4 SAFETY REQUIREMENTS FOR ELECTRICAL WIRING WORKS IN RESIDENTIAL BUILDINGS
            • Why Electric Shocks Occur
            • INSTALLATION CIRCUITS AND SYSTEMS
            • Working Principal of Star-Delta Starter
            • Star-delta Starter Consists following units
            • Power Circuit of Star Delta Starter
            • Control Circuit of Star-Delta Starter (Open Transition)
            • What is Open or Closed Transition Starting
            • Effect of Transient in Starter (Open Transient starter)
            • Size of each part of Star-Delta starter
            • Motor Starting Characteristics of Star-Delta Starter
            • Advantages of Star-Delta starter
            • Disadvantages of Star-Delta starter
            • Features of star-delta starting
            • Application of Star-Delta Starter
            • LESSON 1 WIRING SYSTEM OF SINGLE PHASE DISTRIBUTION BOARD
            • LESSON 2 WIRING SYSTEM OF SINGLE PHASE LIGHTING CIRCUIT
            • LESSON 3ndash WIRING SYSTEM OF SINGLE PHASE POWER CIRCUIT
            • LESSON 4ndash CONDUIT BENDING AND TRUNKING FABRICATION TECHNIQUE
            • LESSON 5 ndashWIRING SYSTEM OF 1 Oslash LIGHTING AND POWER CIRCUIT
              • POWER CIRCUITS
                • LESSON 6 ndash WIRING SYSTEM OF 3 Oslash DISTRIBUTION BOARD
                • LESSON 7 ndash WIRING SYSTEM OF THREE PHASE LIGHTING AND POWER CIRCUIT
                • LESSON 8 INSPECTION AND TESTING OF ELECTRICAL INSTALLATION
                  • CONTINUITY TEST
                    • Polarity Test
                      • Earth Electrode Resistance Test
                      • Earth Electrode Resistance Measurement Method (Figure 86)
                        • Residual Current Device Test
                        • LESSON 9 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (DC)
                        • LESSON 10 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (AC)
                        • LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE
                        • LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
                          • LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
                          • LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
                          • LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
                            • a Dead circuit test
                            • b Life circuit test
                            • LESSON 16
                              • TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
                              • SELF-ASSESSMENT QUESTIONS
Page 31: WorksheetTask AMIN

EZTECH ELECTRICAL INSTALLATION GUIDE

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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

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EZTECH ELECTRICAL INSTALLATION GUIDE

Objectives

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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

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EZTECH ELECTRICAL INSTALLATION GUIDE

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EZTECH ELECTRICAL INSTALLATION GUIDE

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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

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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

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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

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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

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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

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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

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4 1048766 Carry out test as in the Table below

5 1048766 Meter reading value shall be less than 1 Megaohm

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Insulation resitance test

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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

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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

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Polarity test

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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

  • ELECTRICITY SUPPLY SPECIFICATIONS
    • Legal Requirements
    • Determining Consumer Load Requirements
    • 2 CONTROL AND PROTECTION SYSTEM FOR ELECTRICAL WIRING
    • CABLE SELECTION
      • 32 Factors Related to Cable Current Carrying Capacity
      • Functions and Colour Identification of Non Flexible Cables
        • Conductor Insulation and Types of Wiring
        • Functions and Colour Identification of Non Flexible Cables
        • 3 SELECTION OF WIRING ACCESSORIES
        • EARTHING OF ELECTRICAL INSTALLATIONS
          • 4 SAFETY REQUIREMENTS FOR ELECTRICAL WIRING WORKS IN RESIDENTIAL BUILDINGS
            • Why Electric Shocks Occur
            • INSTALLATION CIRCUITS AND SYSTEMS
            • Working Principal of Star-Delta Starter
            • Star-delta Starter Consists following units
            • Power Circuit of Star Delta Starter
            • Control Circuit of Star-Delta Starter (Open Transition)
            • What is Open or Closed Transition Starting
            • Effect of Transient in Starter (Open Transient starter)
            • Size of each part of Star-Delta starter
            • Motor Starting Characteristics of Star-Delta Starter
            • Advantages of Star-Delta starter
            • Disadvantages of Star-Delta starter
            • Features of star-delta starting
            • Application of Star-Delta Starter
            • LESSON 1 WIRING SYSTEM OF SINGLE PHASE DISTRIBUTION BOARD
            • LESSON 2 WIRING SYSTEM OF SINGLE PHASE LIGHTING CIRCUIT
            • LESSON 3ndash WIRING SYSTEM OF SINGLE PHASE POWER CIRCUIT
            • LESSON 4ndash CONDUIT BENDING AND TRUNKING FABRICATION TECHNIQUE
            • LESSON 5 ndashWIRING SYSTEM OF 1 Oslash LIGHTING AND POWER CIRCUIT
              • POWER CIRCUITS
                • LESSON 6 ndash WIRING SYSTEM OF 3 Oslash DISTRIBUTION BOARD
                • LESSON 7 ndash WIRING SYSTEM OF THREE PHASE LIGHTING AND POWER CIRCUIT
                • LESSON 8 INSPECTION AND TESTING OF ELECTRICAL INSTALLATION
                  • CONTINUITY TEST
                    • Polarity Test
                      • Earth Electrode Resistance Test
                      • Earth Electrode Resistance Measurement Method (Figure 86)
                        • Residual Current Device Test
                        • LESSON 9 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (DC)
                        • LESSON 10 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (AC)
                        • LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE
                        • LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
                          • LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
                          • LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
                          • LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
                            • a Dead circuit test
                            • b Life circuit test
                            • LESSON 16
                              • TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
                              • SELF-ASSESSMENT QUESTIONS
Page 32: WorksheetTask AMIN

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

  • ELECTRICITY SUPPLY SPECIFICATIONS
    • Legal Requirements
    • Determining Consumer Load Requirements
    • 2 CONTROL AND PROTECTION SYSTEM FOR ELECTRICAL WIRING
    • CABLE SELECTION
      • 32 Factors Related to Cable Current Carrying Capacity
      • Functions and Colour Identification of Non Flexible Cables
        • Conductor Insulation and Types of Wiring
        • Functions and Colour Identification of Non Flexible Cables
        • 3 SELECTION OF WIRING ACCESSORIES
        • EARTHING OF ELECTRICAL INSTALLATIONS
          • 4 SAFETY REQUIREMENTS FOR ELECTRICAL WIRING WORKS IN RESIDENTIAL BUILDINGS
            • Why Electric Shocks Occur
            • INSTALLATION CIRCUITS AND SYSTEMS
            • Working Principal of Star-Delta Starter
            • Star-delta Starter Consists following units
            • Power Circuit of Star Delta Starter
            • Control Circuit of Star-Delta Starter (Open Transition)
            • What is Open or Closed Transition Starting
            • Effect of Transient in Starter (Open Transient starter)
            • Size of each part of Star-Delta starter
            • Motor Starting Characteristics of Star-Delta Starter
            • Advantages of Star-Delta starter
            • Disadvantages of Star-Delta starter
            • Features of star-delta starting
            • Application of Star-Delta Starter
            • LESSON 1 WIRING SYSTEM OF SINGLE PHASE DISTRIBUTION BOARD
            • LESSON 2 WIRING SYSTEM OF SINGLE PHASE LIGHTING CIRCUIT
            • LESSON 3ndash WIRING SYSTEM OF SINGLE PHASE POWER CIRCUIT
            • LESSON 4ndash CONDUIT BENDING AND TRUNKING FABRICATION TECHNIQUE
            • LESSON 5 ndashWIRING SYSTEM OF 1 Oslash LIGHTING AND POWER CIRCUIT
              • POWER CIRCUITS
                • LESSON 6 ndash WIRING SYSTEM OF 3 Oslash DISTRIBUTION BOARD
                • LESSON 7 ndash WIRING SYSTEM OF THREE PHASE LIGHTING AND POWER CIRCUIT
                • LESSON 8 INSPECTION AND TESTING OF ELECTRICAL INSTALLATION
                  • CONTINUITY TEST
                    • Polarity Test
                      • Earth Electrode Resistance Test
                      • Earth Electrode Resistance Measurement Method (Figure 86)
                        • Residual Current Device Test
                        • LESSON 9 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (DC)
                        • LESSON 10 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (AC)
                        • LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE
                        • LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
                          • LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
                          • LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
                          • LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
                            • a Dead circuit test
                            • b Life circuit test
                            • LESSON 16
                              • TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
                              • SELF-ASSESSMENT QUESTIONS
Page 33: WorksheetTask AMIN

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

  • ELECTRICITY SUPPLY SPECIFICATIONS
    • Legal Requirements
    • Determining Consumer Load Requirements
    • 2 CONTROL AND PROTECTION SYSTEM FOR ELECTRICAL WIRING
    • CABLE SELECTION
      • 32 Factors Related to Cable Current Carrying Capacity
      • Functions and Colour Identification of Non Flexible Cables
        • Conductor Insulation and Types of Wiring
        • Functions and Colour Identification of Non Flexible Cables
        • 3 SELECTION OF WIRING ACCESSORIES
        • EARTHING OF ELECTRICAL INSTALLATIONS
          • 4 SAFETY REQUIREMENTS FOR ELECTRICAL WIRING WORKS IN RESIDENTIAL BUILDINGS
            • Why Electric Shocks Occur
            • INSTALLATION CIRCUITS AND SYSTEMS
            • Working Principal of Star-Delta Starter
            • Star-delta Starter Consists following units
            • Power Circuit of Star Delta Starter
            • Control Circuit of Star-Delta Starter (Open Transition)
            • What is Open or Closed Transition Starting
            • Effect of Transient in Starter (Open Transient starter)
            • Size of each part of Star-Delta starter
            • Motor Starting Characteristics of Star-Delta Starter
            • Advantages of Star-Delta starter
            • Disadvantages of Star-Delta starter
            • Features of star-delta starting
            • Application of Star-Delta Starter
            • LESSON 1 WIRING SYSTEM OF SINGLE PHASE DISTRIBUTION BOARD
            • LESSON 2 WIRING SYSTEM OF SINGLE PHASE LIGHTING CIRCUIT
            • LESSON 3ndash WIRING SYSTEM OF SINGLE PHASE POWER CIRCUIT
            • LESSON 4ndash CONDUIT BENDING AND TRUNKING FABRICATION TECHNIQUE
            • LESSON 5 ndashWIRING SYSTEM OF 1 Oslash LIGHTING AND POWER CIRCUIT
              • POWER CIRCUITS
                • LESSON 6 ndash WIRING SYSTEM OF 3 Oslash DISTRIBUTION BOARD
                • LESSON 7 ndash WIRING SYSTEM OF THREE PHASE LIGHTING AND POWER CIRCUIT
                • LESSON 8 INSPECTION AND TESTING OF ELECTRICAL INSTALLATION
                  • CONTINUITY TEST
                    • Polarity Test
                      • Earth Electrode Resistance Test
                      • Earth Electrode Resistance Measurement Method (Figure 86)
                        • Residual Current Device Test
                        • LESSON 9 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (DC)
                        • LESSON 10 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (AC)
                        • LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE
                        • LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
                          • LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
                          • LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
                          • LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
                            • a Dead circuit test
                            • b Life circuit test
                            • LESSON 16
                              • TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
                              • SELF-ASSESSMENT QUESTIONS
Page 34: WorksheetTask AMIN

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

  • ELECTRICITY SUPPLY SPECIFICATIONS
    • Legal Requirements
    • Determining Consumer Load Requirements
    • 2 CONTROL AND PROTECTION SYSTEM FOR ELECTRICAL WIRING
    • CABLE SELECTION
      • 32 Factors Related to Cable Current Carrying Capacity
      • Functions and Colour Identification of Non Flexible Cables
        • Conductor Insulation and Types of Wiring
        • Functions and Colour Identification of Non Flexible Cables
        • 3 SELECTION OF WIRING ACCESSORIES
        • EARTHING OF ELECTRICAL INSTALLATIONS
          • 4 SAFETY REQUIREMENTS FOR ELECTRICAL WIRING WORKS IN RESIDENTIAL BUILDINGS
            • Why Electric Shocks Occur
            • INSTALLATION CIRCUITS AND SYSTEMS
            • Working Principal of Star-Delta Starter
            • Star-delta Starter Consists following units
            • Power Circuit of Star Delta Starter
            • Control Circuit of Star-Delta Starter (Open Transition)
            • What is Open or Closed Transition Starting
            • Effect of Transient in Starter (Open Transient starter)
            • Size of each part of Star-Delta starter
            • Motor Starting Characteristics of Star-Delta Starter
            • Advantages of Star-Delta starter
            • Disadvantages of Star-Delta starter
            • Features of star-delta starting
            • Application of Star-Delta Starter
            • LESSON 1 WIRING SYSTEM OF SINGLE PHASE DISTRIBUTION BOARD
            • LESSON 2 WIRING SYSTEM OF SINGLE PHASE LIGHTING CIRCUIT
            • LESSON 3ndash WIRING SYSTEM OF SINGLE PHASE POWER CIRCUIT
            • LESSON 4ndash CONDUIT BENDING AND TRUNKING FABRICATION TECHNIQUE
            • LESSON 5 ndashWIRING SYSTEM OF 1 Oslash LIGHTING AND POWER CIRCUIT
              • POWER CIRCUITS
                • LESSON 6 ndash WIRING SYSTEM OF 3 Oslash DISTRIBUTION BOARD
                • LESSON 7 ndash WIRING SYSTEM OF THREE PHASE LIGHTING AND POWER CIRCUIT
                • LESSON 8 INSPECTION AND TESTING OF ELECTRICAL INSTALLATION
                  • CONTINUITY TEST
                    • Polarity Test
                      • Earth Electrode Resistance Test
                      • Earth Electrode Resistance Measurement Method (Figure 86)
                        • Residual Current Device Test
                        • LESSON 9 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (DC)
                        • LESSON 10 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (AC)
                        • LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE
                        • LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
                          • LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
                          • LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
                          • LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
                            • a Dead circuit test
                            • b Life circuit test
                            • LESSON 16
                              • TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
                              • SELF-ASSESSMENT QUESTIONS
Page 35: WorksheetTask AMIN

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

  • ELECTRICITY SUPPLY SPECIFICATIONS
    • Legal Requirements
    • Determining Consumer Load Requirements
    • 2 CONTROL AND PROTECTION SYSTEM FOR ELECTRICAL WIRING
    • CABLE SELECTION
      • 32 Factors Related to Cable Current Carrying Capacity
      • Functions and Colour Identification of Non Flexible Cables
        • Conductor Insulation and Types of Wiring
        • Functions and Colour Identification of Non Flexible Cables
        • 3 SELECTION OF WIRING ACCESSORIES
        • EARTHING OF ELECTRICAL INSTALLATIONS
          • 4 SAFETY REQUIREMENTS FOR ELECTRICAL WIRING WORKS IN RESIDENTIAL BUILDINGS
            • Why Electric Shocks Occur
            • INSTALLATION CIRCUITS AND SYSTEMS
            • Working Principal of Star-Delta Starter
            • Star-delta Starter Consists following units
            • Power Circuit of Star Delta Starter
            • Control Circuit of Star-Delta Starter (Open Transition)
            • What is Open or Closed Transition Starting
            • Effect of Transient in Starter (Open Transient starter)
            • Size of each part of Star-Delta starter
            • Motor Starting Characteristics of Star-Delta Starter
            • Advantages of Star-Delta starter
            • Disadvantages of Star-Delta starter
            • Features of star-delta starting
            • Application of Star-Delta Starter
            • LESSON 1 WIRING SYSTEM OF SINGLE PHASE DISTRIBUTION BOARD
            • LESSON 2 WIRING SYSTEM OF SINGLE PHASE LIGHTING CIRCUIT
            • LESSON 3ndash WIRING SYSTEM OF SINGLE PHASE POWER CIRCUIT
            • LESSON 4ndash CONDUIT BENDING AND TRUNKING FABRICATION TECHNIQUE
            • LESSON 5 ndashWIRING SYSTEM OF 1 Oslash LIGHTING AND POWER CIRCUIT
              • POWER CIRCUITS
                • LESSON 6 ndash WIRING SYSTEM OF 3 Oslash DISTRIBUTION BOARD
                • LESSON 7 ndash WIRING SYSTEM OF THREE PHASE LIGHTING AND POWER CIRCUIT
                • LESSON 8 INSPECTION AND TESTING OF ELECTRICAL INSTALLATION
                  • CONTINUITY TEST
                    • Polarity Test
                      • Earth Electrode Resistance Test
                      • Earth Electrode Resistance Measurement Method (Figure 86)
                        • Residual Current Device Test
                        • LESSON 9 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (DC)
                        • LESSON 10 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (AC)
                        • LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE
                        • LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
                          • LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
                          • LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
                          • LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
                            • a Dead circuit test
                            • b Life circuit test
                            • LESSON 16
                              • TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
                              • SELF-ASSESSMENT QUESTIONS
Page 36: WorksheetTask AMIN

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

  • ELECTRICITY SUPPLY SPECIFICATIONS
    • Legal Requirements
    • Determining Consumer Load Requirements
    • 2 CONTROL AND PROTECTION SYSTEM FOR ELECTRICAL WIRING
    • CABLE SELECTION
      • 32 Factors Related to Cable Current Carrying Capacity
      • Functions and Colour Identification of Non Flexible Cables
        • Conductor Insulation and Types of Wiring
        • Functions and Colour Identification of Non Flexible Cables
        • 3 SELECTION OF WIRING ACCESSORIES
        • EARTHING OF ELECTRICAL INSTALLATIONS
          • 4 SAFETY REQUIREMENTS FOR ELECTRICAL WIRING WORKS IN RESIDENTIAL BUILDINGS
            • Why Electric Shocks Occur
            • INSTALLATION CIRCUITS AND SYSTEMS
            • Working Principal of Star-Delta Starter
            • Star-delta Starter Consists following units
            • Power Circuit of Star Delta Starter
            • Control Circuit of Star-Delta Starter (Open Transition)
            • What is Open or Closed Transition Starting
            • Effect of Transient in Starter (Open Transient starter)
            • Size of each part of Star-Delta starter
            • Motor Starting Characteristics of Star-Delta Starter
            • Advantages of Star-Delta starter
            • Disadvantages of Star-Delta starter
            • Features of star-delta starting
            • Application of Star-Delta Starter
            • LESSON 1 WIRING SYSTEM OF SINGLE PHASE DISTRIBUTION BOARD
            • LESSON 2 WIRING SYSTEM OF SINGLE PHASE LIGHTING CIRCUIT
            • LESSON 3ndash WIRING SYSTEM OF SINGLE PHASE POWER CIRCUIT
            • LESSON 4ndash CONDUIT BENDING AND TRUNKING FABRICATION TECHNIQUE
            • LESSON 5 ndashWIRING SYSTEM OF 1 Oslash LIGHTING AND POWER CIRCUIT
              • POWER CIRCUITS
                • LESSON 6 ndash WIRING SYSTEM OF 3 Oslash DISTRIBUTION BOARD
                • LESSON 7 ndash WIRING SYSTEM OF THREE PHASE LIGHTING AND POWER CIRCUIT
                • LESSON 8 INSPECTION AND TESTING OF ELECTRICAL INSTALLATION
                  • CONTINUITY TEST
                    • Polarity Test
                      • Earth Electrode Resistance Test
                      • Earth Electrode Resistance Measurement Method (Figure 86)
                        • Residual Current Device Test
                        • LESSON 9 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (DC)
                        • LESSON 10 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (AC)
                        • LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE
                        • LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
                          • LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
                          • LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
                          • LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
                            • a Dead circuit test
                            • b Life circuit test
                            • LESSON 16
                              • TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
                              • SELF-ASSESSMENT QUESTIONS
Page 37: WorksheetTask AMIN

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

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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

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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

  • ELECTRICITY SUPPLY SPECIFICATIONS
    • Legal Requirements
    • Determining Consumer Load Requirements
    • 2 CONTROL AND PROTECTION SYSTEM FOR ELECTRICAL WIRING
    • CABLE SELECTION
      • 32 Factors Related to Cable Current Carrying Capacity
      • Functions and Colour Identification of Non Flexible Cables
        • Conductor Insulation and Types of Wiring
        • Functions and Colour Identification of Non Flexible Cables
        • 3 SELECTION OF WIRING ACCESSORIES
        • EARTHING OF ELECTRICAL INSTALLATIONS
          • 4 SAFETY REQUIREMENTS FOR ELECTRICAL WIRING WORKS IN RESIDENTIAL BUILDINGS
            • Why Electric Shocks Occur
            • INSTALLATION CIRCUITS AND SYSTEMS
            • Working Principal of Star-Delta Starter
            • Star-delta Starter Consists following units
            • Power Circuit of Star Delta Starter
            • Control Circuit of Star-Delta Starter (Open Transition)
            • What is Open or Closed Transition Starting
            • Effect of Transient in Starter (Open Transient starter)
            • Size of each part of Star-Delta starter
            • Motor Starting Characteristics of Star-Delta Starter
            • Advantages of Star-Delta starter
            • Disadvantages of Star-Delta starter
            • Features of star-delta starting
            • Application of Star-Delta Starter
            • LESSON 1 WIRING SYSTEM OF SINGLE PHASE DISTRIBUTION BOARD
            • LESSON 2 WIRING SYSTEM OF SINGLE PHASE LIGHTING CIRCUIT
            • LESSON 3ndash WIRING SYSTEM OF SINGLE PHASE POWER CIRCUIT
            • LESSON 4ndash CONDUIT BENDING AND TRUNKING FABRICATION TECHNIQUE
            • LESSON 5 ndashWIRING SYSTEM OF 1 Oslash LIGHTING AND POWER CIRCUIT
              • POWER CIRCUITS
                • LESSON 6 ndash WIRING SYSTEM OF 3 Oslash DISTRIBUTION BOARD
                • LESSON 7 ndash WIRING SYSTEM OF THREE PHASE LIGHTING AND POWER CIRCUIT
                • LESSON 8 INSPECTION AND TESTING OF ELECTRICAL INSTALLATION
                  • CONTINUITY TEST
                    • Polarity Test
                      • Earth Electrode Resistance Test
                      • Earth Electrode Resistance Measurement Method (Figure 86)
                        • Residual Current Device Test
                        • LESSON 9 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (DC)
                        • LESSON 10 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (AC)
                        • LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE
                        • LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
                          • LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
                          • LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
                          • LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
                            • a Dead circuit test
                            • b Life circuit test
                            • LESSON 16
                              • TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
                              • SELF-ASSESSMENT QUESTIONS
Page 38: WorksheetTask AMIN

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

  • ELECTRICITY SUPPLY SPECIFICATIONS
    • Legal Requirements
    • Determining Consumer Load Requirements
    • 2 CONTROL AND PROTECTION SYSTEM FOR ELECTRICAL WIRING
    • CABLE SELECTION
      • 32 Factors Related to Cable Current Carrying Capacity
      • Functions and Colour Identification of Non Flexible Cables
        • Conductor Insulation and Types of Wiring
        • Functions and Colour Identification of Non Flexible Cables
        • 3 SELECTION OF WIRING ACCESSORIES
        • EARTHING OF ELECTRICAL INSTALLATIONS
          • 4 SAFETY REQUIREMENTS FOR ELECTRICAL WIRING WORKS IN RESIDENTIAL BUILDINGS
            • Why Electric Shocks Occur
            • INSTALLATION CIRCUITS AND SYSTEMS
            • Working Principal of Star-Delta Starter
            • Star-delta Starter Consists following units
            • Power Circuit of Star Delta Starter
            • Control Circuit of Star-Delta Starter (Open Transition)
            • What is Open or Closed Transition Starting
            • Effect of Transient in Starter (Open Transient starter)
            • Size of each part of Star-Delta starter
            • Motor Starting Characteristics of Star-Delta Starter
            • Advantages of Star-Delta starter
            • Disadvantages of Star-Delta starter
            • Features of star-delta starting
            • Application of Star-Delta Starter
            • LESSON 1 WIRING SYSTEM OF SINGLE PHASE DISTRIBUTION BOARD
            • LESSON 2 WIRING SYSTEM OF SINGLE PHASE LIGHTING CIRCUIT
            • LESSON 3ndash WIRING SYSTEM OF SINGLE PHASE POWER CIRCUIT
            • LESSON 4ndash CONDUIT BENDING AND TRUNKING FABRICATION TECHNIQUE
            • LESSON 5 ndashWIRING SYSTEM OF 1 Oslash LIGHTING AND POWER CIRCUIT
              • POWER CIRCUITS
                • LESSON 6 ndash WIRING SYSTEM OF 3 Oslash DISTRIBUTION BOARD
                • LESSON 7 ndash WIRING SYSTEM OF THREE PHASE LIGHTING AND POWER CIRCUIT
                • LESSON 8 INSPECTION AND TESTING OF ELECTRICAL INSTALLATION
                  • CONTINUITY TEST
                    • Polarity Test
                      • Earth Electrode Resistance Test
                      • Earth Electrode Resistance Measurement Method (Figure 86)
                        • Residual Current Device Test
                        • LESSON 9 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (DC)
                        • LESSON 10 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (AC)
                        • LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE
                        • LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
                          • LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
                          • LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
                          • LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
                            • a Dead circuit test
                            • b Life circuit test
                            • LESSON 16
                              • TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
                              • SELF-ASSESSMENT QUESTIONS
Page 39: WorksheetTask AMIN

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

  • ELECTRICITY SUPPLY SPECIFICATIONS
    • Legal Requirements
    • Determining Consumer Load Requirements
    • 2 CONTROL AND PROTECTION SYSTEM FOR ELECTRICAL WIRING
    • CABLE SELECTION
      • 32 Factors Related to Cable Current Carrying Capacity
      • Functions and Colour Identification of Non Flexible Cables
        • Conductor Insulation and Types of Wiring
        • Functions and Colour Identification of Non Flexible Cables
        • 3 SELECTION OF WIRING ACCESSORIES
        • EARTHING OF ELECTRICAL INSTALLATIONS
          • 4 SAFETY REQUIREMENTS FOR ELECTRICAL WIRING WORKS IN RESIDENTIAL BUILDINGS
            • Why Electric Shocks Occur
            • INSTALLATION CIRCUITS AND SYSTEMS
            • Working Principal of Star-Delta Starter
            • Star-delta Starter Consists following units
            • Power Circuit of Star Delta Starter
            • Control Circuit of Star-Delta Starter (Open Transition)
            • What is Open or Closed Transition Starting
            • Effect of Transient in Starter (Open Transient starter)
            • Size of each part of Star-Delta starter
            • Motor Starting Characteristics of Star-Delta Starter
            • Advantages of Star-Delta starter
            • Disadvantages of Star-Delta starter
            • Features of star-delta starting
            • Application of Star-Delta Starter
            • LESSON 1 WIRING SYSTEM OF SINGLE PHASE DISTRIBUTION BOARD
            • LESSON 2 WIRING SYSTEM OF SINGLE PHASE LIGHTING CIRCUIT
            • LESSON 3ndash WIRING SYSTEM OF SINGLE PHASE POWER CIRCUIT
            • LESSON 4ndash CONDUIT BENDING AND TRUNKING FABRICATION TECHNIQUE
            • LESSON 5 ndashWIRING SYSTEM OF 1 Oslash LIGHTING AND POWER CIRCUIT
              • POWER CIRCUITS
                • LESSON 6 ndash WIRING SYSTEM OF 3 Oslash DISTRIBUTION BOARD
                • LESSON 7 ndash WIRING SYSTEM OF THREE PHASE LIGHTING AND POWER CIRCUIT
                • LESSON 8 INSPECTION AND TESTING OF ELECTRICAL INSTALLATION
                  • CONTINUITY TEST
                    • Polarity Test
                      • Earth Electrode Resistance Test
                      • Earth Electrode Resistance Measurement Method (Figure 86)
                        • Residual Current Device Test
                        • LESSON 9 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (DC)
                        • LESSON 10 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (AC)
                        • LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE
                        • LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
                          • LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
                          • LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
                          • LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
                            • a Dead circuit test
                            • b Life circuit test
                            • LESSON 16
                              • TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
                              • SELF-ASSESSMENT QUESTIONS
Page 40: WorksheetTask AMIN

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

  • ELECTRICITY SUPPLY SPECIFICATIONS
    • Legal Requirements
    • Determining Consumer Load Requirements
    • 2 CONTROL AND PROTECTION SYSTEM FOR ELECTRICAL WIRING
    • CABLE SELECTION
      • 32 Factors Related to Cable Current Carrying Capacity
      • Functions and Colour Identification of Non Flexible Cables
        • Conductor Insulation and Types of Wiring
        • Functions and Colour Identification of Non Flexible Cables
        • 3 SELECTION OF WIRING ACCESSORIES
        • EARTHING OF ELECTRICAL INSTALLATIONS
          • 4 SAFETY REQUIREMENTS FOR ELECTRICAL WIRING WORKS IN RESIDENTIAL BUILDINGS
            • Why Electric Shocks Occur
            • INSTALLATION CIRCUITS AND SYSTEMS
            • Working Principal of Star-Delta Starter
            • Star-delta Starter Consists following units
            • Power Circuit of Star Delta Starter
            • Control Circuit of Star-Delta Starter (Open Transition)
            • What is Open or Closed Transition Starting
            • Effect of Transient in Starter (Open Transient starter)
            • Size of each part of Star-Delta starter
            • Motor Starting Characteristics of Star-Delta Starter
            • Advantages of Star-Delta starter
            • Disadvantages of Star-Delta starter
            • Features of star-delta starting
            • Application of Star-Delta Starter
            • LESSON 1 WIRING SYSTEM OF SINGLE PHASE DISTRIBUTION BOARD
            • LESSON 2 WIRING SYSTEM OF SINGLE PHASE LIGHTING CIRCUIT
            • LESSON 3ndash WIRING SYSTEM OF SINGLE PHASE POWER CIRCUIT
            • LESSON 4ndash CONDUIT BENDING AND TRUNKING FABRICATION TECHNIQUE
            • LESSON 5 ndashWIRING SYSTEM OF 1 Oslash LIGHTING AND POWER CIRCUIT
              • POWER CIRCUITS
                • LESSON 6 ndash WIRING SYSTEM OF 3 Oslash DISTRIBUTION BOARD
                • LESSON 7 ndash WIRING SYSTEM OF THREE PHASE LIGHTING AND POWER CIRCUIT
                • LESSON 8 INSPECTION AND TESTING OF ELECTRICAL INSTALLATION
                  • CONTINUITY TEST
                    • Polarity Test
                      • Earth Electrode Resistance Test
                      • Earth Electrode Resistance Measurement Method (Figure 86)
                        • Residual Current Device Test
                        • LESSON 9 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (DC)
                        • LESSON 10 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (AC)
                        • LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE
                        • LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
                          • LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
                          • LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
                          • LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
                            • a Dead circuit test
                            • b Life circuit test
                            • LESSON 16
                              • TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
                              • SELF-ASSESSMENT QUESTIONS
Page 41: WorksheetTask AMIN

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

  • ELECTRICITY SUPPLY SPECIFICATIONS
    • Legal Requirements
    • Determining Consumer Load Requirements
    • 2 CONTROL AND PROTECTION SYSTEM FOR ELECTRICAL WIRING
    • CABLE SELECTION
      • 32 Factors Related to Cable Current Carrying Capacity
      • Functions and Colour Identification of Non Flexible Cables
        • Conductor Insulation and Types of Wiring
        • Functions and Colour Identification of Non Flexible Cables
        • 3 SELECTION OF WIRING ACCESSORIES
        • EARTHING OF ELECTRICAL INSTALLATIONS
          • 4 SAFETY REQUIREMENTS FOR ELECTRICAL WIRING WORKS IN RESIDENTIAL BUILDINGS
            • Why Electric Shocks Occur
            • INSTALLATION CIRCUITS AND SYSTEMS
            • Working Principal of Star-Delta Starter
            • Star-delta Starter Consists following units
            • Power Circuit of Star Delta Starter
            • Control Circuit of Star-Delta Starter (Open Transition)
            • What is Open or Closed Transition Starting
            • Effect of Transient in Starter (Open Transient starter)
            • Size of each part of Star-Delta starter
            • Motor Starting Characteristics of Star-Delta Starter
            • Advantages of Star-Delta starter
            • Disadvantages of Star-Delta starter
            • Features of star-delta starting
            • Application of Star-Delta Starter
            • LESSON 1 WIRING SYSTEM OF SINGLE PHASE DISTRIBUTION BOARD
            • LESSON 2 WIRING SYSTEM OF SINGLE PHASE LIGHTING CIRCUIT
            • LESSON 3ndash WIRING SYSTEM OF SINGLE PHASE POWER CIRCUIT
            • LESSON 4ndash CONDUIT BENDING AND TRUNKING FABRICATION TECHNIQUE
            • LESSON 5 ndashWIRING SYSTEM OF 1 Oslash LIGHTING AND POWER CIRCUIT
              • POWER CIRCUITS
                • LESSON 6 ndash WIRING SYSTEM OF 3 Oslash DISTRIBUTION BOARD
                • LESSON 7 ndash WIRING SYSTEM OF THREE PHASE LIGHTING AND POWER CIRCUIT
                • LESSON 8 INSPECTION AND TESTING OF ELECTRICAL INSTALLATION
                  • CONTINUITY TEST
                    • Polarity Test
                      • Earth Electrode Resistance Test
                      • Earth Electrode Resistance Measurement Method (Figure 86)
                        • Residual Current Device Test
                        • LESSON 9 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (DC)
                        • LESSON 10 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (AC)
                        • LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE
                        • LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
                          • LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
                          • LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
                          • LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
                            • a Dead circuit test
                            • b Life circuit test
                            • LESSON 16
                              • TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
                              • SELF-ASSESSMENT QUESTIONS
Page 42: WorksheetTask AMIN

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

  • ELECTRICITY SUPPLY SPECIFICATIONS
    • Legal Requirements
    • Determining Consumer Load Requirements
    • 2 CONTROL AND PROTECTION SYSTEM FOR ELECTRICAL WIRING
    • CABLE SELECTION
      • 32 Factors Related to Cable Current Carrying Capacity
      • Functions and Colour Identification of Non Flexible Cables
        • Conductor Insulation and Types of Wiring
        • Functions and Colour Identification of Non Flexible Cables
        • 3 SELECTION OF WIRING ACCESSORIES
        • EARTHING OF ELECTRICAL INSTALLATIONS
          • 4 SAFETY REQUIREMENTS FOR ELECTRICAL WIRING WORKS IN RESIDENTIAL BUILDINGS
            • Why Electric Shocks Occur
            • INSTALLATION CIRCUITS AND SYSTEMS
            • Working Principal of Star-Delta Starter
            • Star-delta Starter Consists following units
            • Power Circuit of Star Delta Starter
            • Control Circuit of Star-Delta Starter (Open Transition)
            • What is Open or Closed Transition Starting
            • Effect of Transient in Starter (Open Transient starter)
            • Size of each part of Star-Delta starter
            • Motor Starting Characteristics of Star-Delta Starter
            • Advantages of Star-Delta starter
            • Disadvantages of Star-Delta starter
            • Features of star-delta starting
            • Application of Star-Delta Starter
            • LESSON 1 WIRING SYSTEM OF SINGLE PHASE DISTRIBUTION BOARD
            • LESSON 2 WIRING SYSTEM OF SINGLE PHASE LIGHTING CIRCUIT
            • LESSON 3ndash WIRING SYSTEM OF SINGLE PHASE POWER CIRCUIT
            • LESSON 4ndash CONDUIT BENDING AND TRUNKING FABRICATION TECHNIQUE
            • LESSON 5 ndashWIRING SYSTEM OF 1 Oslash LIGHTING AND POWER CIRCUIT
              • POWER CIRCUITS
                • LESSON 6 ndash WIRING SYSTEM OF 3 Oslash DISTRIBUTION BOARD
                • LESSON 7 ndash WIRING SYSTEM OF THREE PHASE LIGHTING AND POWER CIRCUIT
                • LESSON 8 INSPECTION AND TESTING OF ELECTRICAL INSTALLATION
                  • CONTINUITY TEST
                    • Polarity Test
                      • Earth Electrode Resistance Test
                      • Earth Electrode Resistance Measurement Method (Figure 86)
                        • Residual Current Device Test
                        • LESSON 9 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (DC)
                        • LESSON 10 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (AC)
                        • LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE
                        • LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
                          • LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
                          • LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
                          • LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
                            • a Dead circuit test
                            • b Life circuit test
                            • LESSON 16
                              • TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
                              • SELF-ASSESSMENT QUESTIONS
Page 43: WorksheetTask AMIN

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

  • ELECTRICITY SUPPLY SPECIFICATIONS
    • Legal Requirements
    • Determining Consumer Load Requirements
    • 2 CONTROL AND PROTECTION SYSTEM FOR ELECTRICAL WIRING
    • CABLE SELECTION
      • 32 Factors Related to Cable Current Carrying Capacity
      • Functions and Colour Identification of Non Flexible Cables
        • Conductor Insulation and Types of Wiring
        • Functions and Colour Identification of Non Flexible Cables
        • 3 SELECTION OF WIRING ACCESSORIES
        • EARTHING OF ELECTRICAL INSTALLATIONS
          • 4 SAFETY REQUIREMENTS FOR ELECTRICAL WIRING WORKS IN RESIDENTIAL BUILDINGS
            • Why Electric Shocks Occur
            • INSTALLATION CIRCUITS AND SYSTEMS
            • Working Principal of Star-Delta Starter
            • Star-delta Starter Consists following units
            • Power Circuit of Star Delta Starter
            • Control Circuit of Star-Delta Starter (Open Transition)
            • What is Open or Closed Transition Starting
            • Effect of Transient in Starter (Open Transient starter)
            • Size of each part of Star-Delta starter
            • Motor Starting Characteristics of Star-Delta Starter
            • Advantages of Star-Delta starter
            • Disadvantages of Star-Delta starter
            • Features of star-delta starting
            • Application of Star-Delta Starter
            • LESSON 1 WIRING SYSTEM OF SINGLE PHASE DISTRIBUTION BOARD
            • LESSON 2 WIRING SYSTEM OF SINGLE PHASE LIGHTING CIRCUIT
            • LESSON 3ndash WIRING SYSTEM OF SINGLE PHASE POWER CIRCUIT
            • LESSON 4ndash CONDUIT BENDING AND TRUNKING FABRICATION TECHNIQUE
            • LESSON 5 ndashWIRING SYSTEM OF 1 Oslash LIGHTING AND POWER CIRCUIT
              • POWER CIRCUITS
                • LESSON 6 ndash WIRING SYSTEM OF 3 Oslash DISTRIBUTION BOARD
                • LESSON 7 ndash WIRING SYSTEM OF THREE PHASE LIGHTING AND POWER CIRCUIT
                • LESSON 8 INSPECTION AND TESTING OF ELECTRICAL INSTALLATION
                  • CONTINUITY TEST
                    • Polarity Test
                      • Earth Electrode Resistance Test
                      • Earth Electrode Resistance Measurement Method (Figure 86)
                        • Residual Current Device Test
                        • LESSON 9 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (DC)
                        • LESSON 10 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (AC)
                        • LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE
                        • LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
                          • LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
                          • LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
                          • LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
                            • a Dead circuit test
                            • b Life circuit test
                            • LESSON 16
                              • TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
                              • SELF-ASSESSMENT QUESTIONS
Page 44: WorksheetTask AMIN

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

  • ELECTRICITY SUPPLY SPECIFICATIONS
    • Legal Requirements
    • Determining Consumer Load Requirements
    • 2 CONTROL AND PROTECTION SYSTEM FOR ELECTRICAL WIRING
    • CABLE SELECTION
      • 32 Factors Related to Cable Current Carrying Capacity
      • Functions and Colour Identification of Non Flexible Cables
        • Conductor Insulation and Types of Wiring
        • Functions and Colour Identification of Non Flexible Cables
        • 3 SELECTION OF WIRING ACCESSORIES
        • EARTHING OF ELECTRICAL INSTALLATIONS
          • 4 SAFETY REQUIREMENTS FOR ELECTRICAL WIRING WORKS IN RESIDENTIAL BUILDINGS
            • Why Electric Shocks Occur
            • INSTALLATION CIRCUITS AND SYSTEMS
            • Working Principal of Star-Delta Starter
            • Star-delta Starter Consists following units
            • Power Circuit of Star Delta Starter
            • Control Circuit of Star-Delta Starter (Open Transition)
            • What is Open or Closed Transition Starting
            • Effect of Transient in Starter (Open Transient starter)
            • Size of each part of Star-Delta starter
            • Motor Starting Characteristics of Star-Delta Starter
            • Advantages of Star-Delta starter
            • Disadvantages of Star-Delta starter
            • Features of star-delta starting
            • Application of Star-Delta Starter
            • LESSON 1 WIRING SYSTEM OF SINGLE PHASE DISTRIBUTION BOARD
            • LESSON 2 WIRING SYSTEM OF SINGLE PHASE LIGHTING CIRCUIT
            • LESSON 3ndash WIRING SYSTEM OF SINGLE PHASE POWER CIRCUIT
            • LESSON 4ndash CONDUIT BENDING AND TRUNKING FABRICATION TECHNIQUE
            • LESSON 5 ndashWIRING SYSTEM OF 1 Oslash LIGHTING AND POWER CIRCUIT
              • POWER CIRCUITS
                • LESSON 6 ndash WIRING SYSTEM OF 3 Oslash DISTRIBUTION BOARD
                • LESSON 7 ndash WIRING SYSTEM OF THREE PHASE LIGHTING AND POWER CIRCUIT
                • LESSON 8 INSPECTION AND TESTING OF ELECTRICAL INSTALLATION
                  • CONTINUITY TEST
                    • Polarity Test
                      • Earth Electrode Resistance Test
                      • Earth Electrode Resistance Measurement Method (Figure 86)
                        • Residual Current Device Test
                        • LESSON 9 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (DC)
                        • LESSON 10 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (AC)
                        • LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE
                        • LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
                          • LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
                          • LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
                          • LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
                            • a Dead circuit test
                            • b Life circuit test
                            • LESSON 16
                              • TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
                              • SELF-ASSESSMENT QUESTIONS
Page 45: WorksheetTask AMIN

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

  • ELECTRICITY SUPPLY SPECIFICATIONS
    • Legal Requirements
    • Determining Consumer Load Requirements
    • 2 CONTROL AND PROTECTION SYSTEM FOR ELECTRICAL WIRING
    • CABLE SELECTION
      • 32 Factors Related to Cable Current Carrying Capacity
      • Functions and Colour Identification of Non Flexible Cables
        • Conductor Insulation and Types of Wiring
        • Functions and Colour Identification of Non Flexible Cables
        • 3 SELECTION OF WIRING ACCESSORIES
        • EARTHING OF ELECTRICAL INSTALLATIONS
          • 4 SAFETY REQUIREMENTS FOR ELECTRICAL WIRING WORKS IN RESIDENTIAL BUILDINGS
            • Why Electric Shocks Occur
            • INSTALLATION CIRCUITS AND SYSTEMS
            • Working Principal of Star-Delta Starter
            • Star-delta Starter Consists following units
            • Power Circuit of Star Delta Starter
            • Control Circuit of Star-Delta Starter (Open Transition)
            • What is Open or Closed Transition Starting
            • Effect of Transient in Starter (Open Transient starter)
            • Size of each part of Star-Delta starter
            • Motor Starting Characteristics of Star-Delta Starter
            • Advantages of Star-Delta starter
            • Disadvantages of Star-Delta starter
            • Features of star-delta starting
            • Application of Star-Delta Starter
            • LESSON 1 WIRING SYSTEM OF SINGLE PHASE DISTRIBUTION BOARD
            • LESSON 2 WIRING SYSTEM OF SINGLE PHASE LIGHTING CIRCUIT
            • LESSON 3ndash WIRING SYSTEM OF SINGLE PHASE POWER CIRCUIT
            • LESSON 4ndash CONDUIT BENDING AND TRUNKING FABRICATION TECHNIQUE
            • LESSON 5 ndashWIRING SYSTEM OF 1 Oslash LIGHTING AND POWER CIRCUIT
              • POWER CIRCUITS
                • LESSON 6 ndash WIRING SYSTEM OF 3 Oslash DISTRIBUTION BOARD
                • LESSON 7 ndash WIRING SYSTEM OF THREE PHASE LIGHTING AND POWER CIRCUIT
                • LESSON 8 INSPECTION AND TESTING OF ELECTRICAL INSTALLATION
                  • CONTINUITY TEST
                    • Polarity Test
                      • Earth Electrode Resistance Test
                      • Earth Electrode Resistance Measurement Method (Figure 86)
                        • Residual Current Device Test
                        • LESSON 9 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (DC)
                        • LESSON 10 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (AC)
                        • LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE
                        • LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
                          • LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
                          • LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
                          • LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
                            • a Dead circuit test
                            • b Life circuit test
                            • LESSON 16
                              • TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
                              • SELF-ASSESSMENT QUESTIONS
Page 46: WorksheetTask AMIN

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

  • ELECTRICITY SUPPLY SPECIFICATIONS
    • Legal Requirements
    • Determining Consumer Load Requirements
    • 2 CONTROL AND PROTECTION SYSTEM FOR ELECTRICAL WIRING
    • CABLE SELECTION
      • 32 Factors Related to Cable Current Carrying Capacity
      • Functions and Colour Identification of Non Flexible Cables
        • Conductor Insulation and Types of Wiring
        • Functions and Colour Identification of Non Flexible Cables
        • 3 SELECTION OF WIRING ACCESSORIES
        • EARTHING OF ELECTRICAL INSTALLATIONS
          • 4 SAFETY REQUIREMENTS FOR ELECTRICAL WIRING WORKS IN RESIDENTIAL BUILDINGS
            • Why Electric Shocks Occur
            • INSTALLATION CIRCUITS AND SYSTEMS
            • Working Principal of Star-Delta Starter
            • Star-delta Starter Consists following units
            • Power Circuit of Star Delta Starter
            • Control Circuit of Star-Delta Starter (Open Transition)
            • What is Open or Closed Transition Starting
            • Effect of Transient in Starter (Open Transient starter)
            • Size of each part of Star-Delta starter
            • Motor Starting Characteristics of Star-Delta Starter
            • Advantages of Star-Delta starter
            • Disadvantages of Star-Delta starter
            • Features of star-delta starting
            • Application of Star-Delta Starter
            • LESSON 1 WIRING SYSTEM OF SINGLE PHASE DISTRIBUTION BOARD
            • LESSON 2 WIRING SYSTEM OF SINGLE PHASE LIGHTING CIRCUIT
            • LESSON 3ndash WIRING SYSTEM OF SINGLE PHASE POWER CIRCUIT
            • LESSON 4ndash CONDUIT BENDING AND TRUNKING FABRICATION TECHNIQUE
            • LESSON 5 ndashWIRING SYSTEM OF 1 Oslash LIGHTING AND POWER CIRCUIT
              • POWER CIRCUITS
                • LESSON 6 ndash WIRING SYSTEM OF 3 Oslash DISTRIBUTION BOARD
                • LESSON 7 ndash WIRING SYSTEM OF THREE PHASE LIGHTING AND POWER CIRCUIT
                • LESSON 8 INSPECTION AND TESTING OF ELECTRICAL INSTALLATION
                  • CONTINUITY TEST
                    • Polarity Test
                      • Earth Electrode Resistance Test
                      • Earth Electrode Resistance Measurement Method (Figure 86)
                        • Residual Current Device Test
                        • LESSON 9 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (DC)
                        • LESSON 10 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (AC)
                        • LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE
                        • LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
                          • LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
                          • LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
                          • LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
                            • a Dead circuit test
                            • b Life circuit test
                            • LESSON 16
                              • TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
                              • SELF-ASSESSMENT QUESTIONS
Page 47: WorksheetTask AMIN

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

  • ELECTRICITY SUPPLY SPECIFICATIONS
    • Legal Requirements
    • Determining Consumer Load Requirements
    • 2 CONTROL AND PROTECTION SYSTEM FOR ELECTRICAL WIRING
    • CABLE SELECTION
      • 32 Factors Related to Cable Current Carrying Capacity
      • Functions and Colour Identification of Non Flexible Cables
        • Conductor Insulation and Types of Wiring
        • Functions and Colour Identification of Non Flexible Cables
        • 3 SELECTION OF WIRING ACCESSORIES
        • EARTHING OF ELECTRICAL INSTALLATIONS
          • 4 SAFETY REQUIREMENTS FOR ELECTRICAL WIRING WORKS IN RESIDENTIAL BUILDINGS
            • Why Electric Shocks Occur
            • INSTALLATION CIRCUITS AND SYSTEMS
            • Working Principal of Star-Delta Starter
            • Star-delta Starter Consists following units
            • Power Circuit of Star Delta Starter
            • Control Circuit of Star-Delta Starter (Open Transition)
            • What is Open or Closed Transition Starting
            • Effect of Transient in Starter (Open Transient starter)
            • Size of each part of Star-Delta starter
            • Motor Starting Characteristics of Star-Delta Starter
            • Advantages of Star-Delta starter
            • Disadvantages of Star-Delta starter
            • Features of star-delta starting
            • Application of Star-Delta Starter
            • LESSON 1 WIRING SYSTEM OF SINGLE PHASE DISTRIBUTION BOARD
            • LESSON 2 WIRING SYSTEM OF SINGLE PHASE LIGHTING CIRCUIT
            • LESSON 3ndash WIRING SYSTEM OF SINGLE PHASE POWER CIRCUIT
            • LESSON 4ndash CONDUIT BENDING AND TRUNKING FABRICATION TECHNIQUE
            • LESSON 5 ndashWIRING SYSTEM OF 1 Oslash LIGHTING AND POWER CIRCUIT
              • POWER CIRCUITS
                • LESSON 6 ndash WIRING SYSTEM OF 3 Oslash DISTRIBUTION BOARD
                • LESSON 7 ndash WIRING SYSTEM OF THREE PHASE LIGHTING AND POWER CIRCUIT
                • LESSON 8 INSPECTION AND TESTING OF ELECTRICAL INSTALLATION
                  • CONTINUITY TEST
                    • Polarity Test
                      • Earth Electrode Resistance Test
                      • Earth Electrode Resistance Measurement Method (Figure 86)
                        • Residual Current Device Test
                        • LESSON 9 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (DC)
                        • LESSON 10 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (AC)
                        • LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE
                        • LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
                          • LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
                          • LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
                          • LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
                            • a Dead circuit test
                            • b Life circuit test
                            • LESSON 16
                              • TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
                              • SELF-ASSESSMENT QUESTIONS
Page 48: WorksheetTask AMIN

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

  • ELECTRICITY SUPPLY SPECIFICATIONS
    • Legal Requirements
    • Determining Consumer Load Requirements
    • 2 CONTROL AND PROTECTION SYSTEM FOR ELECTRICAL WIRING
    • CABLE SELECTION
      • 32 Factors Related to Cable Current Carrying Capacity
      • Functions and Colour Identification of Non Flexible Cables
        • Conductor Insulation and Types of Wiring
        • Functions and Colour Identification of Non Flexible Cables
        • 3 SELECTION OF WIRING ACCESSORIES
        • EARTHING OF ELECTRICAL INSTALLATIONS
          • 4 SAFETY REQUIREMENTS FOR ELECTRICAL WIRING WORKS IN RESIDENTIAL BUILDINGS
            • Why Electric Shocks Occur
            • INSTALLATION CIRCUITS AND SYSTEMS
            • Working Principal of Star-Delta Starter
            • Star-delta Starter Consists following units
            • Power Circuit of Star Delta Starter
            • Control Circuit of Star-Delta Starter (Open Transition)
            • What is Open or Closed Transition Starting
            • Effect of Transient in Starter (Open Transient starter)
            • Size of each part of Star-Delta starter
            • Motor Starting Characteristics of Star-Delta Starter
            • Advantages of Star-Delta starter
            • Disadvantages of Star-Delta starter
            • Features of star-delta starting
            • Application of Star-Delta Starter
            • LESSON 1 WIRING SYSTEM OF SINGLE PHASE DISTRIBUTION BOARD
            • LESSON 2 WIRING SYSTEM OF SINGLE PHASE LIGHTING CIRCUIT
            • LESSON 3ndash WIRING SYSTEM OF SINGLE PHASE POWER CIRCUIT
            • LESSON 4ndash CONDUIT BENDING AND TRUNKING FABRICATION TECHNIQUE
            • LESSON 5 ndashWIRING SYSTEM OF 1 Oslash LIGHTING AND POWER CIRCUIT
              • POWER CIRCUITS
                • LESSON 6 ndash WIRING SYSTEM OF 3 Oslash DISTRIBUTION BOARD
                • LESSON 7 ndash WIRING SYSTEM OF THREE PHASE LIGHTING AND POWER CIRCUIT
                • LESSON 8 INSPECTION AND TESTING OF ELECTRICAL INSTALLATION
                  • CONTINUITY TEST
                    • Polarity Test
                      • Earth Electrode Resistance Test
                      • Earth Electrode Resistance Measurement Method (Figure 86)
                        • Residual Current Device Test
                        • LESSON 9 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (DC)
                        • LESSON 10 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (AC)
                        • LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE
                        • LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
                          • LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
                          • LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
                          • LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
                            • a Dead circuit test
                            • b Life circuit test
                            • LESSON 16
                              • TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
                              • SELF-ASSESSMENT QUESTIONS
Page 49: WorksheetTask AMIN

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

  • ELECTRICITY SUPPLY SPECIFICATIONS
    • Legal Requirements
    • Determining Consumer Load Requirements
    • 2 CONTROL AND PROTECTION SYSTEM FOR ELECTRICAL WIRING
    • CABLE SELECTION
      • 32 Factors Related to Cable Current Carrying Capacity
      • Functions and Colour Identification of Non Flexible Cables
        • Conductor Insulation and Types of Wiring
        • Functions and Colour Identification of Non Flexible Cables
        • 3 SELECTION OF WIRING ACCESSORIES
        • EARTHING OF ELECTRICAL INSTALLATIONS
          • 4 SAFETY REQUIREMENTS FOR ELECTRICAL WIRING WORKS IN RESIDENTIAL BUILDINGS
            • Why Electric Shocks Occur
            • INSTALLATION CIRCUITS AND SYSTEMS
            • Working Principal of Star-Delta Starter
            • Star-delta Starter Consists following units
            • Power Circuit of Star Delta Starter
            • Control Circuit of Star-Delta Starter (Open Transition)
            • What is Open or Closed Transition Starting
            • Effect of Transient in Starter (Open Transient starter)
            • Size of each part of Star-Delta starter
            • Motor Starting Characteristics of Star-Delta Starter
            • Advantages of Star-Delta starter
            • Disadvantages of Star-Delta starter
            • Features of star-delta starting
            • Application of Star-Delta Starter
            • LESSON 1 WIRING SYSTEM OF SINGLE PHASE DISTRIBUTION BOARD
            • LESSON 2 WIRING SYSTEM OF SINGLE PHASE LIGHTING CIRCUIT
            • LESSON 3ndash WIRING SYSTEM OF SINGLE PHASE POWER CIRCUIT
            • LESSON 4ndash CONDUIT BENDING AND TRUNKING FABRICATION TECHNIQUE
            • LESSON 5 ndashWIRING SYSTEM OF 1 Oslash LIGHTING AND POWER CIRCUIT
              • POWER CIRCUITS
                • LESSON 6 ndash WIRING SYSTEM OF 3 Oslash DISTRIBUTION BOARD
                • LESSON 7 ndash WIRING SYSTEM OF THREE PHASE LIGHTING AND POWER CIRCUIT
                • LESSON 8 INSPECTION AND TESTING OF ELECTRICAL INSTALLATION
                  • CONTINUITY TEST
                    • Polarity Test
                      • Earth Electrode Resistance Test
                      • Earth Electrode Resistance Measurement Method (Figure 86)
                        • Residual Current Device Test
                        • LESSON 9 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (DC)
                        • LESSON 10 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (AC)
                        • LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE
                        • LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
                          • LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
                          • LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
                          • LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
                            • a Dead circuit test
                            • b Life circuit test
                            • LESSON 16
                              • TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
                              • SELF-ASSESSMENT QUESTIONS
Page 50: WorksheetTask AMIN

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

  • ELECTRICITY SUPPLY SPECIFICATIONS
    • Legal Requirements
    • Determining Consumer Load Requirements
    • 2 CONTROL AND PROTECTION SYSTEM FOR ELECTRICAL WIRING
    • CABLE SELECTION
      • 32 Factors Related to Cable Current Carrying Capacity
      • Functions and Colour Identification of Non Flexible Cables
        • Conductor Insulation and Types of Wiring
        • Functions and Colour Identification of Non Flexible Cables
        • 3 SELECTION OF WIRING ACCESSORIES
        • EARTHING OF ELECTRICAL INSTALLATIONS
          • 4 SAFETY REQUIREMENTS FOR ELECTRICAL WIRING WORKS IN RESIDENTIAL BUILDINGS
            • Why Electric Shocks Occur
            • INSTALLATION CIRCUITS AND SYSTEMS
            • Working Principal of Star-Delta Starter
            • Star-delta Starter Consists following units
            • Power Circuit of Star Delta Starter
            • Control Circuit of Star-Delta Starter (Open Transition)
            • What is Open or Closed Transition Starting
            • Effect of Transient in Starter (Open Transient starter)
            • Size of each part of Star-Delta starter
            • Motor Starting Characteristics of Star-Delta Starter
            • Advantages of Star-Delta starter
            • Disadvantages of Star-Delta starter
            • Features of star-delta starting
            • Application of Star-Delta Starter
            • LESSON 1 WIRING SYSTEM OF SINGLE PHASE DISTRIBUTION BOARD
            • LESSON 2 WIRING SYSTEM OF SINGLE PHASE LIGHTING CIRCUIT
            • LESSON 3ndash WIRING SYSTEM OF SINGLE PHASE POWER CIRCUIT
            • LESSON 4ndash CONDUIT BENDING AND TRUNKING FABRICATION TECHNIQUE
            • LESSON 5 ndashWIRING SYSTEM OF 1 Oslash LIGHTING AND POWER CIRCUIT
              • POWER CIRCUITS
                • LESSON 6 ndash WIRING SYSTEM OF 3 Oslash DISTRIBUTION BOARD
                • LESSON 7 ndash WIRING SYSTEM OF THREE PHASE LIGHTING AND POWER CIRCUIT
                • LESSON 8 INSPECTION AND TESTING OF ELECTRICAL INSTALLATION
                  • CONTINUITY TEST
                    • Polarity Test
                      • Earth Electrode Resistance Test
                      • Earth Electrode Resistance Measurement Method (Figure 86)
                        • Residual Current Device Test
                        • LESSON 9 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (DC)
                        • LESSON 10 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (AC)
                        • LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE
                        • LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
                          • LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
                          • LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
                          • LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
                            • a Dead circuit test
                            • b Life circuit test
                            • LESSON 16
                              • TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
                              • SELF-ASSESSMENT QUESTIONS
Page 51: WorksheetTask AMIN

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

  • ELECTRICITY SUPPLY SPECIFICATIONS
    • Legal Requirements
    • Determining Consumer Load Requirements
    • 2 CONTROL AND PROTECTION SYSTEM FOR ELECTRICAL WIRING
    • CABLE SELECTION
      • 32 Factors Related to Cable Current Carrying Capacity
      • Functions and Colour Identification of Non Flexible Cables
        • Conductor Insulation and Types of Wiring
        • Functions and Colour Identification of Non Flexible Cables
        • 3 SELECTION OF WIRING ACCESSORIES
        • EARTHING OF ELECTRICAL INSTALLATIONS
          • 4 SAFETY REQUIREMENTS FOR ELECTRICAL WIRING WORKS IN RESIDENTIAL BUILDINGS
            • Why Electric Shocks Occur
            • INSTALLATION CIRCUITS AND SYSTEMS
            • Working Principal of Star-Delta Starter
            • Star-delta Starter Consists following units
            • Power Circuit of Star Delta Starter
            • Control Circuit of Star-Delta Starter (Open Transition)
            • What is Open or Closed Transition Starting
            • Effect of Transient in Starter (Open Transient starter)
            • Size of each part of Star-Delta starter
            • Motor Starting Characteristics of Star-Delta Starter
            • Advantages of Star-Delta starter
            • Disadvantages of Star-Delta starter
            • Features of star-delta starting
            • Application of Star-Delta Starter
            • LESSON 1 WIRING SYSTEM OF SINGLE PHASE DISTRIBUTION BOARD
            • LESSON 2 WIRING SYSTEM OF SINGLE PHASE LIGHTING CIRCUIT
            • LESSON 3ndash WIRING SYSTEM OF SINGLE PHASE POWER CIRCUIT
            • LESSON 4ndash CONDUIT BENDING AND TRUNKING FABRICATION TECHNIQUE
            • LESSON 5 ndashWIRING SYSTEM OF 1 Oslash LIGHTING AND POWER CIRCUIT
              • POWER CIRCUITS
                • LESSON 6 ndash WIRING SYSTEM OF 3 Oslash DISTRIBUTION BOARD
                • LESSON 7 ndash WIRING SYSTEM OF THREE PHASE LIGHTING AND POWER CIRCUIT
                • LESSON 8 INSPECTION AND TESTING OF ELECTRICAL INSTALLATION
                  • CONTINUITY TEST
                    • Polarity Test
                      • Earth Electrode Resistance Test
                      • Earth Electrode Resistance Measurement Method (Figure 86)
                        • Residual Current Device Test
                        • LESSON 9 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (DC)
                        • LESSON 10 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (AC)
                        • LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE
                        • LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
                          • LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
                          • LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
                          • LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
                            • a Dead circuit test
                            • b Life circuit test
                            • LESSON 16
                              • TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
                              • SELF-ASSESSMENT QUESTIONS
Page 52: WorksheetTask AMIN

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

  • ELECTRICITY SUPPLY SPECIFICATIONS
    • Legal Requirements
    • Determining Consumer Load Requirements
    • 2 CONTROL AND PROTECTION SYSTEM FOR ELECTRICAL WIRING
    • CABLE SELECTION
      • 32 Factors Related to Cable Current Carrying Capacity
      • Functions and Colour Identification of Non Flexible Cables
        • Conductor Insulation and Types of Wiring
        • Functions and Colour Identification of Non Flexible Cables
        • 3 SELECTION OF WIRING ACCESSORIES
        • EARTHING OF ELECTRICAL INSTALLATIONS
          • 4 SAFETY REQUIREMENTS FOR ELECTRICAL WIRING WORKS IN RESIDENTIAL BUILDINGS
            • Why Electric Shocks Occur
            • INSTALLATION CIRCUITS AND SYSTEMS
            • Working Principal of Star-Delta Starter
            • Star-delta Starter Consists following units
            • Power Circuit of Star Delta Starter
            • Control Circuit of Star-Delta Starter (Open Transition)
            • What is Open or Closed Transition Starting
            • Effect of Transient in Starter (Open Transient starter)
            • Size of each part of Star-Delta starter
            • Motor Starting Characteristics of Star-Delta Starter
            • Advantages of Star-Delta starter
            • Disadvantages of Star-Delta starter
            • Features of star-delta starting
            • Application of Star-Delta Starter
            • LESSON 1 WIRING SYSTEM OF SINGLE PHASE DISTRIBUTION BOARD
            • LESSON 2 WIRING SYSTEM OF SINGLE PHASE LIGHTING CIRCUIT
            • LESSON 3ndash WIRING SYSTEM OF SINGLE PHASE POWER CIRCUIT
            • LESSON 4ndash CONDUIT BENDING AND TRUNKING FABRICATION TECHNIQUE
            • LESSON 5 ndashWIRING SYSTEM OF 1 Oslash LIGHTING AND POWER CIRCUIT
              • POWER CIRCUITS
                • LESSON 6 ndash WIRING SYSTEM OF 3 Oslash DISTRIBUTION BOARD
                • LESSON 7 ndash WIRING SYSTEM OF THREE PHASE LIGHTING AND POWER CIRCUIT
                • LESSON 8 INSPECTION AND TESTING OF ELECTRICAL INSTALLATION
                  • CONTINUITY TEST
                    • Polarity Test
                      • Earth Electrode Resistance Test
                      • Earth Electrode Resistance Measurement Method (Figure 86)
                        • Residual Current Device Test
                        • LESSON 9 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (DC)
                        • LESSON 10 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (AC)
                        • LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE
                        • LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
                          • LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
                          • LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
                          • LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
                            • a Dead circuit test
                            • b Life circuit test
                            • LESSON 16
                              • TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
                              • SELF-ASSESSMENT QUESTIONS
Page 53: WorksheetTask AMIN

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

  • ELECTRICITY SUPPLY SPECIFICATIONS
    • Legal Requirements
    • Determining Consumer Load Requirements
    • 2 CONTROL AND PROTECTION SYSTEM FOR ELECTRICAL WIRING
    • CABLE SELECTION
      • 32 Factors Related to Cable Current Carrying Capacity
      • Functions and Colour Identification of Non Flexible Cables
        • Conductor Insulation and Types of Wiring
        • Functions and Colour Identification of Non Flexible Cables
        • 3 SELECTION OF WIRING ACCESSORIES
        • EARTHING OF ELECTRICAL INSTALLATIONS
          • 4 SAFETY REQUIREMENTS FOR ELECTRICAL WIRING WORKS IN RESIDENTIAL BUILDINGS
            • Why Electric Shocks Occur
            • INSTALLATION CIRCUITS AND SYSTEMS
            • Working Principal of Star-Delta Starter
            • Star-delta Starter Consists following units
            • Power Circuit of Star Delta Starter
            • Control Circuit of Star-Delta Starter (Open Transition)
            • What is Open or Closed Transition Starting
            • Effect of Transient in Starter (Open Transient starter)
            • Size of each part of Star-Delta starter
            • Motor Starting Characteristics of Star-Delta Starter
            • Advantages of Star-Delta starter
            • Disadvantages of Star-Delta starter
            • Features of star-delta starting
            • Application of Star-Delta Starter
            • LESSON 1 WIRING SYSTEM OF SINGLE PHASE DISTRIBUTION BOARD
            • LESSON 2 WIRING SYSTEM OF SINGLE PHASE LIGHTING CIRCUIT
            • LESSON 3ndash WIRING SYSTEM OF SINGLE PHASE POWER CIRCUIT
            • LESSON 4ndash CONDUIT BENDING AND TRUNKING FABRICATION TECHNIQUE
            • LESSON 5 ndashWIRING SYSTEM OF 1 Oslash LIGHTING AND POWER CIRCUIT
              • POWER CIRCUITS
                • LESSON 6 ndash WIRING SYSTEM OF 3 Oslash DISTRIBUTION BOARD
                • LESSON 7 ndash WIRING SYSTEM OF THREE PHASE LIGHTING AND POWER CIRCUIT
                • LESSON 8 INSPECTION AND TESTING OF ELECTRICAL INSTALLATION
                  • CONTINUITY TEST
                    • Polarity Test
                      • Earth Electrode Resistance Test
                      • Earth Electrode Resistance Measurement Method (Figure 86)
                        • Residual Current Device Test
                        • LESSON 9 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (DC)
                        • LESSON 10 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (AC)
                        • LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE
                        • LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
                          • LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
                          • LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
                          • LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
                            • a Dead circuit test
                            • b Life circuit test
                            • LESSON 16
                              • TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
                              • SELF-ASSESSMENT QUESTIONS
Page 54: WorksheetTask AMIN

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

  • ELECTRICITY SUPPLY SPECIFICATIONS
    • Legal Requirements
    • Determining Consumer Load Requirements
    • 2 CONTROL AND PROTECTION SYSTEM FOR ELECTRICAL WIRING
    • CABLE SELECTION
      • 32 Factors Related to Cable Current Carrying Capacity
      • Functions and Colour Identification of Non Flexible Cables
        • Conductor Insulation and Types of Wiring
        • Functions and Colour Identification of Non Flexible Cables
        • 3 SELECTION OF WIRING ACCESSORIES
        • EARTHING OF ELECTRICAL INSTALLATIONS
          • 4 SAFETY REQUIREMENTS FOR ELECTRICAL WIRING WORKS IN RESIDENTIAL BUILDINGS
            • Why Electric Shocks Occur
            • INSTALLATION CIRCUITS AND SYSTEMS
            • Working Principal of Star-Delta Starter
            • Star-delta Starter Consists following units
            • Power Circuit of Star Delta Starter
            • Control Circuit of Star-Delta Starter (Open Transition)
            • What is Open or Closed Transition Starting
            • Effect of Transient in Starter (Open Transient starter)
            • Size of each part of Star-Delta starter
            • Motor Starting Characteristics of Star-Delta Starter
            • Advantages of Star-Delta starter
            • Disadvantages of Star-Delta starter
            • Features of star-delta starting
            • Application of Star-Delta Starter
            • LESSON 1 WIRING SYSTEM OF SINGLE PHASE DISTRIBUTION BOARD
            • LESSON 2 WIRING SYSTEM OF SINGLE PHASE LIGHTING CIRCUIT
            • LESSON 3ndash WIRING SYSTEM OF SINGLE PHASE POWER CIRCUIT
            • LESSON 4ndash CONDUIT BENDING AND TRUNKING FABRICATION TECHNIQUE
            • LESSON 5 ndashWIRING SYSTEM OF 1 Oslash LIGHTING AND POWER CIRCUIT
              • POWER CIRCUITS
                • LESSON 6 ndash WIRING SYSTEM OF 3 Oslash DISTRIBUTION BOARD
                • LESSON 7 ndash WIRING SYSTEM OF THREE PHASE LIGHTING AND POWER CIRCUIT
                • LESSON 8 INSPECTION AND TESTING OF ELECTRICAL INSTALLATION
                  • CONTINUITY TEST
                    • Polarity Test
                      • Earth Electrode Resistance Test
                      • Earth Electrode Resistance Measurement Method (Figure 86)
                        • Residual Current Device Test
                        • LESSON 9 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (DC)
                        • LESSON 10 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (AC)
                        • LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE
                        • LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
                          • LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
                          • LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
                          • LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
                            • a Dead circuit test
                            • b Life circuit test
                            • LESSON 16
                              • TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
                              • SELF-ASSESSMENT QUESTIONS
Page 55: WorksheetTask AMIN

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

  • ELECTRICITY SUPPLY SPECIFICATIONS
    • Legal Requirements
    • Determining Consumer Load Requirements
    • 2 CONTROL AND PROTECTION SYSTEM FOR ELECTRICAL WIRING
    • CABLE SELECTION
      • 32 Factors Related to Cable Current Carrying Capacity
      • Functions and Colour Identification of Non Flexible Cables
        • Conductor Insulation and Types of Wiring
        • Functions and Colour Identification of Non Flexible Cables
        • 3 SELECTION OF WIRING ACCESSORIES
        • EARTHING OF ELECTRICAL INSTALLATIONS
          • 4 SAFETY REQUIREMENTS FOR ELECTRICAL WIRING WORKS IN RESIDENTIAL BUILDINGS
            • Why Electric Shocks Occur
            • INSTALLATION CIRCUITS AND SYSTEMS
            • Working Principal of Star-Delta Starter
            • Star-delta Starter Consists following units
            • Power Circuit of Star Delta Starter
            • Control Circuit of Star-Delta Starter (Open Transition)
            • What is Open or Closed Transition Starting
            • Effect of Transient in Starter (Open Transient starter)
            • Size of each part of Star-Delta starter
            • Motor Starting Characteristics of Star-Delta Starter
            • Advantages of Star-Delta starter
            • Disadvantages of Star-Delta starter
            • Features of star-delta starting
            • Application of Star-Delta Starter
            • LESSON 1 WIRING SYSTEM OF SINGLE PHASE DISTRIBUTION BOARD
            • LESSON 2 WIRING SYSTEM OF SINGLE PHASE LIGHTING CIRCUIT
            • LESSON 3ndash WIRING SYSTEM OF SINGLE PHASE POWER CIRCUIT
            • LESSON 4ndash CONDUIT BENDING AND TRUNKING FABRICATION TECHNIQUE
            • LESSON 5 ndashWIRING SYSTEM OF 1 Oslash LIGHTING AND POWER CIRCUIT
              • POWER CIRCUITS
                • LESSON 6 ndash WIRING SYSTEM OF 3 Oslash DISTRIBUTION BOARD
                • LESSON 7 ndash WIRING SYSTEM OF THREE PHASE LIGHTING AND POWER CIRCUIT
                • LESSON 8 INSPECTION AND TESTING OF ELECTRICAL INSTALLATION
                  • CONTINUITY TEST
                    • Polarity Test
                      • Earth Electrode Resistance Test
                      • Earth Electrode Resistance Measurement Method (Figure 86)
                        • Residual Current Device Test
                        • LESSON 9 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (DC)
                        • LESSON 10 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (AC)
                        • LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE
                        • LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
                          • LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
                          • LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
                          • LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
                            • a Dead circuit test
                            • b Life circuit test
                            • LESSON 16
                              • TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
                              • SELF-ASSESSMENT QUESTIONS
Page 56: WorksheetTask AMIN

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

  • ELECTRICITY SUPPLY SPECIFICATIONS
    • Legal Requirements
    • Determining Consumer Load Requirements
    • 2 CONTROL AND PROTECTION SYSTEM FOR ELECTRICAL WIRING
    • CABLE SELECTION
      • 32 Factors Related to Cable Current Carrying Capacity
      • Functions and Colour Identification of Non Flexible Cables
        • Conductor Insulation and Types of Wiring
        • Functions and Colour Identification of Non Flexible Cables
        • 3 SELECTION OF WIRING ACCESSORIES
        • EARTHING OF ELECTRICAL INSTALLATIONS
          • 4 SAFETY REQUIREMENTS FOR ELECTRICAL WIRING WORKS IN RESIDENTIAL BUILDINGS
            • Why Electric Shocks Occur
            • INSTALLATION CIRCUITS AND SYSTEMS
            • Working Principal of Star-Delta Starter
            • Star-delta Starter Consists following units
            • Power Circuit of Star Delta Starter
            • Control Circuit of Star-Delta Starter (Open Transition)
            • What is Open or Closed Transition Starting
            • Effect of Transient in Starter (Open Transient starter)
            • Size of each part of Star-Delta starter
            • Motor Starting Characteristics of Star-Delta Starter
            • Advantages of Star-Delta starter
            • Disadvantages of Star-Delta starter
            • Features of star-delta starting
            • Application of Star-Delta Starter
            • LESSON 1 WIRING SYSTEM OF SINGLE PHASE DISTRIBUTION BOARD
            • LESSON 2 WIRING SYSTEM OF SINGLE PHASE LIGHTING CIRCUIT
            • LESSON 3ndash WIRING SYSTEM OF SINGLE PHASE POWER CIRCUIT
            • LESSON 4ndash CONDUIT BENDING AND TRUNKING FABRICATION TECHNIQUE
            • LESSON 5 ndashWIRING SYSTEM OF 1 Oslash LIGHTING AND POWER CIRCUIT
              • POWER CIRCUITS
                • LESSON 6 ndash WIRING SYSTEM OF 3 Oslash DISTRIBUTION BOARD
                • LESSON 7 ndash WIRING SYSTEM OF THREE PHASE LIGHTING AND POWER CIRCUIT
                • LESSON 8 INSPECTION AND TESTING OF ELECTRICAL INSTALLATION
                  • CONTINUITY TEST
                    • Polarity Test
                      • Earth Electrode Resistance Test
                      • Earth Electrode Resistance Measurement Method (Figure 86)
                        • Residual Current Device Test
                        • LESSON 9 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (DC)
                        • LESSON 10 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (AC)
                        • LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE
                        • LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
                          • LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
                          • LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
                          • LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
                            • a Dead circuit test
                            • b Life circuit test
                            • LESSON 16
                              • TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
                              • SELF-ASSESSMENT QUESTIONS
Page 57: WorksheetTask AMIN

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

  • ELECTRICITY SUPPLY SPECIFICATIONS
    • Legal Requirements
    • Determining Consumer Load Requirements
    • 2 CONTROL AND PROTECTION SYSTEM FOR ELECTRICAL WIRING
    • CABLE SELECTION
      • 32 Factors Related to Cable Current Carrying Capacity
      • Functions and Colour Identification of Non Flexible Cables
        • Conductor Insulation and Types of Wiring
        • Functions and Colour Identification of Non Flexible Cables
        • 3 SELECTION OF WIRING ACCESSORIES
        • EARTHING OF ELECTRICAL INSTALLATIONS
          • 4 SAFETY REQUIREMENTS FOR ELECTRICAL WIRING WORKS IN RESIDENTIAL BUILDINGS
            • Why Electric Shocks Occur
            • INSTALLATION CIRCUITS AND SYSTEMS
            • Working Principal of Star-Delta Starter
            • Star-delta Starter Consists following units
            • Power Circuit of Star Delta Starter
            • Control Circuit of Star-Delta Starter (Open Transition)
            • What is Open or Closed Transition Starting
            • Effect of Transient in Starter (Open Transient starter)
            • Size of each part of Star-Delta starter
            • Motor Starting Characteristics of Star-Delta Starter
            • Advantages of Star-Delta starter
            • Disadvantages of Star-Delta starter
            • Features of star-delta starting
            • Application of Star-Delta Starter
            • LESSON 1 WIRING SYSTEM OF SINGLE PHASE DISTRIBUTION BOARD
            • LESSON 2 WIRING SYSTEM OF SINGLE PHASE LIGHTING CIRCUIT
            • LESSON 3ndash WIRING SYSTEM OF SINGLE PHASE POWER CIRCUIT
            • LESSON 4ndash CONDUIT BENDING AND TRUNKING FABRICATION TECHNIQUE
            • LESSON 5 ndashWIRING SYSTEM OF 1 Oslash LIGHTING AND POWER CIRCUIT
              • POWER CIRCUITS
                • LESSON 6 ndash WIRING SYSTEM OF 3 Oslash DISTRIBUTION BOARD
                • LESSON 7 ndash WIRING SYSTEM OF THREE PHASE LIGHTING AND POWER CIRCUIT
                • LESSON 8 INSPECTION AND TESTING OF ELECTRICAL INSTALLATION
                  • CONTINUITY TEST
                    • Polarity Test
                      • Earth Electrode Resistance Test
                      • Earth Electrode Resistance Measurement Method (Figure 86)
                        • Residual Current Device Test
                        • LESSON 9 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (DC)
                        • LESSON 10 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (AC)
                        • LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE
                        • LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
                          • LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
                          • LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
                          • LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
                            • a Dead circuit test
                            • b Life circuit test
                            • LESSON 16
                              • TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
                              • SELF-ASSESSMENT QUESTIONS
Page 58: WorksheetTask AMIN

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

  • ELECTRICITY SUPPLY SPECIFICATIONS
    • Legal Requirements
    • Determining Consumer Load Requirements
    • 2 CONTROL AND PROTECTION SYSTEM FOR ELECTRICAL WIRING
    • CABLE SELECTION
      • 32 Factors Related to Cable Current Carrying Capacity
      • Functions and Colour Identification of Non Flexible Cables
        • Conductor Insulation and Types of Wiring
        • Functions and Colour Identification of Non Flexible Cables
        • 3 SELECTION OF WIRING ACCESSORIES
        • EARTHING OF ELECTRICAL INSTALLATIONS
          • 4 SAFETY REQUIREMENTS FOR ELECTRICAL WIRING WORKS IN RESIDENTIAL BUILDINGS
            • Why Electric Shocks Occur
            • INSTALLATION CIRCUITS AND SYSTEMS
            • Working Principal of Star-Delta Starter
            • Star-delta Starter Consists following units
            • Power Circuit of Star Delta Starter
            • Control Circuit of Star-Delta Starter (Open Transition)
            • What is Open or Closed Transition Starting
            • Effect of Transient in Starter (Open Transient starter)
            • Size of each part of Star-Delta starter
            • Motor Starting Characteristics of Star-Delta Starter
            • Advantages of Star-Delta starter
            • Disadvantages of Star-Delta starter
            • Features of star-delta starting
            • Application of Star-Delta Starter
            • LESSON 1 WIRING SYSTEM OF SINGLE PHASE DISTRIBUTION BOARD
            • LESSON 2 WIRING SYSTEM OF SINGLE PHASE LIGHTING CIRCUIT
            • LESSON 3ndash WIRING SYSTEM OF SINGLE PHASE POWER CIRCUIT
            • LESSON 4ndash CONDUIT BENDING AND TRUNKING FABRICATION TECHNIQUE
            • LESSON 5 ndashWIRING SYSTEM OF 1 Oslash LIGHTING AND POWER CIRCUIT
              • POWER CIRCUITS
                • LESSON 6 ndash WIRING SYSTEM OF 3 Oslash DISTRIBUTION BOARD
                • LESSON 7 ndash WIRING SYSTEM OF THREE PHASE LIGHTING AND POWER CIRCUIT
                • LESSON 8 INSPECTION AND TESTING OF ELECTRICAL INSTALLATION
                  • CONTINUITY TEST
                    • Polarity Test
                      • Earth Electrode Resistance Test
                      • Earth Electrode Resistance Measurement Method (Figure 86)
                        • Residual Current Device Test
                        • LESSON 9 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (DC)
                        • LESSON 10 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (AC)
                        • LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE
                        • LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
                          • LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
                          • LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
                          • LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
                            • a Dead circuit test
                            • b Life circuit test
                            • LESSON 16
                              • TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
                              • SELF-ASSESSMENT QUESTIONS
Page 59: WorksheetTask AMIN

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

  • ELECTRICITY SUPPLY SPECIFICATIONS
    • Legal Requirements
    • Determining Consumer Load Requirements
    • 2 CONTROL AND PROTECTION SYSTEM FOR ELECTRICAL WIRING
    • CABLE SELECTION
      • 32 Factors Related to Cable Current Carrying Capacity
      • Functions and Colour Identification of Non Flexible Cables
        • Conductor Insulation and Types of Wiring
        • Functions and Colour Identification of Non Flexible Cables
        • 3 SELECTION OF WIRING ACCESSORIES
        • EARTHING OF ELECTRICAL INSTALLATIONS
          • 4 SAFETY REQUIREMENTS FOR ELECTRICAL WIRING WORKS IN RESIDENTIAL BUILDINGS
            • Why Electric Shocks Occur
            • INSTALLATION CIRCUITS AND SYSTEMS
            • Working Principal of Star-Delta Starter
            • Star-delta Starter Consists following units
            • Power Circuit of Star Delta Starter
            • Control Circuit of Star-Delta Starter (Open Transition)
            • What is Open or Closed Transition Starting
            • Effect of Transient in Starter (Open Transient starter)
            • Size of each part of Star-Delta starter
            • Motor Starting Characteristics of Star-Delta Starter
            • Advantages of Star-Delta starter
            • Disadvantages of Star-Delta starter
            • Features of star-delta starting
            • Application of Star-Delta Starter
            • LESSON 1 WIRING SYSTEM OF SINGLE PHASE DISTRIBUTION BOARD
            • LESSON 2 WIRING SYSTEM OF SINGLE PHASE LIGHTING CIRCUIT
            • LESSON 3ndash WIRING SYSTEM OF SINGLE PHASE POWER CIRCUIT
            • LESSON 4ndash CONDUIT BENDING AND TRUNKING FABRICATION TECHNIQUE
            • LESSON 5 ndashWIRING SYSTEM OF 1 Oslash LIGHTING AND POWER CIRCUIT
              • POWER CIRCUITS
                • LESSON 6 ndash WIRING SYSTEM OF 3 Oslash DISTRIBUTION BOARD
                • LESSON 7 ndash WIRING SYSTEM OF THREE PHASE LIGHTING AND POWER CIRCUIT
                • LESSON 8 INSPECTION AND TESTING OF ELECTRICAL INSTALLATION
                  • CONTINUITY TEST
                    • Polarity Test
                      • Earth Electrode Resistance Test
                      • Earth Electrode Resistance Measurement Method (Figure 86)
                        • Residual Current Device Test
                        • LESSON 9 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (DC)
                        • LESSON 10 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (AC)
                        • LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE
                        • LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
                          • LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
                          • LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
                          • LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
                            • a Dead circuit test
                            • b Life circuit test
                            • LESSON 16
                              • TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
                              • SELF-ASSESSMENT QUESTIONS
Page 60: WorksheetTask AMIN

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

  • ELECTRICITY SUPPLY SPECIFICATIONS
    • Legal Requirements
    • Determining Consumer Load Requirements
    • 2 CONTROL AND PROTECTION SYSTEM FOR ELECTRICAL WIRING
    • CABLE SELECTION
      • 32 Factors Related to Cable Current Carrying Capacity
      • Functions and Colour Identification of Non Flexible Cables
        • Conductor Insulation and Types of Wiring
        • Functions and Colour Identification of Non Flexible Cables
        • 3 SELECTION OF WIRING ACCESSORIES
        • EARTHING OF ELECTRICAL INSTALLATIONS
          • 4 SAFETY REQUIREMENTS FOR ELECTRICAL WIRING WORKS IN RESIDENTIAL BUILDINGS
            • Why Electric Shocks Occur
            • INSTALLATION CIRCUITS AND SYSTEMS
            • Working Principal of Star-Delta Starter
            • Star-delta Starter Consists following units
            • Power Circuit of Star Delta Starter
            • Control Circuit of Star-Delta Starter (Open Transition)
            • What is Open or Closed Transition Starting
            • Effect of Transient in Starter (Open Transient starter)
            • Size of each part of Star-Delta starter
            • Motor Starting Characteristics of Star-Delta Starter
            • Advantages of Star-Delta starter
            • Disadvantages of Star-Delta starter
            • Features of star-delta starting
            • Application of Star-Delta Starter
            • LESSON 1 WIRING SYSTEM OF SINGLE PHASE DISTRIBUTION BOARD
            • LESSON 2 WIRING SYSTEM OF SINGLE PHASE LIGHTING CIRCUIT
            • LESSON 3ndash WIRING SYSTEM OF SINGLE PHASE POWER CIRCUIT
            • LESSON 4ndash CONDUIT BENDING AND TRUNKING FABRICATION TECHNIQUE
            • LESSON 5 ndashWIRING SYSTEM OF 1 Oslash LIGHTING AND POWER CIRCUIT
              • POWER CIRCUITS
                • LESSON 6 ndash WIRING SYSTEM OF 3 Oslash DISTRIBUTION BOARD
                • LESSON 7 ndash WIRING SYSTEM OF THREE PHASE LIGHTING AND POWER CIRCUIT
                • LESSON 8 INSPECTION AND TESTING OF ELECTRICAL INSTALLATION
                  • CONTINUITY TEST
                    • Polarity Test
                      • Earth Electrode Resistance Test
                      • Earth Electrode Resistance Measurement Method (Figure 86)
                        • Residual Current Device Test
                        • LESSON 9 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (DC)
                        • LESSON 10 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (AC)
                        • LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE
                        • LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
                          • LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
                          • LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
                          • LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
                            • a Dead circuit test
                            • b Life circuit test
                            • LESSON 16
                              • TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
                              • SELF-ASSESSMENT QUESTIONS
Page 61: WorksheetTask AMIN

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

  • ELECTRICITY SUPPLY SPECIFICATIONS
    • Legal Requirements
    • Determining Consumer Load Requirements
    • 2 CONTROL AND PROTECTION SYSTEM FOR ELECTRICAL WIRING
    • CABLE SELECTION
      • 32 Factors Related to Cable Current Carrying Capacity
      • Functions and Colour Identification of Non Flexible Cables
        • Conductor Insulation and Types of Wiring
        • Functions and Colour Identification of Non Flexible Cables
        • 3 SELECTION OF WIRING ACCESSORIES
        • EARTHING OF ELECTRICAL INSTALLATIONS
          • 4 SAFETY REQUIREMENTS FOR ELECTRICAL WIRING WORKS IN RESIDENTIAL BUILDINGS
            • Why Electric Shocks Occur
            • INSTALLATION CIRCUITS AND SYSTEMS
            • Working Principal of Star-Delta Starter
            • Star-delta Starter Consists following units
            • Power Circuit of Star Delta Starter
            • Control Circuit of Star-Delta Starter (Open Transition)
            • What is Open or Closed Transition Starting
            • Effect of Transient in Starter (Open Transient starter)
            • Size of each part of Star-Delta starter
            • Motor Starting Characteristics of Star-Delta Starter
            • Advantages of Star-Delta starter
            • Disadvantages of Star-Delta starter
            • Features of star-delta starting
            • Application of Star-Delta Starter
            • LESSON 1 WIRING SYSTEM OF SINGLE PHASE DISTRIBUTION BOARD
            • LESSON 2 WIRING SYSTEM OF SINGLE PHASE LIGHTING CIRCUIT
            • LESSON 3ndash WIRING SYSTEM OF SINGLE PHASE POWER CIRCUIT
            • LESSON 4ndash CONDUIT BENDING AND TRUNKING FABRICATION TECHNIQUE
            • LESSON 5 ndashWIRING SYSTEM OF 1 Oslash LIGHTING AND POWER CIRCUIT
              • POWER CIRCUITS
                • LESSON 6 ndash WIRING SYSTEM OF 3 Oslash DISTRIBUTION BOARD
                • LESSON 7 ndash WIRING SYSTEM OF THREE PHASE LIGHTING AND POWER CIRCUIT
                • LESSON 8 INSPECTION AND TESTING OF ELECTRICAL INSTALLATION
                  • CONTINUITY TEST
                    • Polarity Test
                      • Earth Electrode Resistance Test
                      • Earth Electrode Resistance Measurement Method (Figure 86)
                        • Residual Current Device Test
                        • LESSON 9 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (DC)
                        • LESSON 10 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (AC)
                        • LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE
                        • LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
                          • LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
                          • LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
                          • LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
                            • a Dead circuit test
                            • b Life circuit test
                            • LESSON 16
                              • TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
                              • SELF-ASSESSMENT QUESTIONS
Page 62: WorksheetTask AMIN

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

  • ELECTRICITY SUPPLY SPECIFICATIONS
    • Legal Requirements
    • Determining Consumer Load Requirements
    • 2 CONTROL AND PROTECTION SYSTEM FOR ELECTRICAL WIRING
    • CABLE SELECTION
      • 32 Factors Related to Cable Current Carrying Capacity
      • Functions and Colour Identification of Non Flexible Cables
        • Conductor Insulation and Types of Wiring
        • Functions and Colour Identification of Non Flexible Cables
        • 3 SELECTION OF WIRING ACCESSORIES
        • EARTHING OF ELECTRICAL INSTALLATIONS
          • 4 SAFETY REQUIREMENTS FOR ELECTRICAL WIRING WORKS IN RESIDENTIAL BUILDINGS
            • Why Electric Shocks Occur
            • INSTALLATION CIRCUITS AND SYSTEMS
            • Working Principal of Star-Delta Starter
            • Star-delta Starter Consists following units
            • Power Circuit of Star Delta Starter
            • Control Circuit of Star-Delta Starter (Open Transition)
            • What is Open or Closed Transition Starting
            • Effect of Transient in Starter (Open Transient starter)
            • Size of each part of Star-Delta starter
            • Motor Starting Characteristics of Star-Delta Starter
            • Advantages of Star-Delta starter
            • Disadvantages of Star-Delta starter
            • Features of star-delta starting
            • Application of Star-Delta Starter
            • LESSON 1 WIRING SYSTEM OF SINGLE PHASE DISTRIBUTION BOARD
            • LESSON 2 WIRING SYSTEM OF SINGLE PHASE LIGHTING CIRCUIT
            • LESSON 3ndash WIRING SYSTEM OF SINGLE PHASE POWER CIRCUIT
            • LESSON 4ndash CONDUIT BENDING AND TRUNKING FABRICATION TECHNIQUE
            • LESSON 5 ndashWIRING SYSTEM OF 1 Oslash LIGHTING AND POWER CIRCUIT
              • POWER CIRCUITS
                • LESSON 6 ndash WIRING SYSTEM OF 3 Oslash DISTRIBUTION BOARD
                • LESSON 7 ndash WIRING SYSTEM OF THREE PHASE LIGHTING AND POWER CIRCUIT
                • LESSON 8 INSPECTION AND TESTING OF ELECTRICAL INSTALLATION
                  • CONTINUITY TEST
                    • Polarity Test
                      • Earth Electrode Resistance Test
                      • Earth Electrode Resistance Measurement Method (Figure 86)
                        • Residual Current Device Test
                        • LESSON 9 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (DC)
                        • LESSON 10 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (AC)
                        • LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE
                        • LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
                          • LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
                          • LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
                          • LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
                            • a Dead circuit test
                            • b Life circuit test
                            • LESSON 16
                              • TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
                              • SELF-ASSESSMENT QUESTIONS
Page 63: WorksheetTask AMIN

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

  • ELECTRICITY SUPPLY SPECIFICATIONS
    • Legal Requirements
    • Determining Consumer Load Requirements
    • 2 CONTROL AND PROTECTION SYSTEM FOR ELECTRICAL WIRING
    • CABLE SELECTION
      • 32 Factors Related to Cable Current Carrying Capacity
      • Functions and Colour Identification of Non Flexible Cables
        • Conductor Insulation and Types of Wiring
        • Functions and Colour Identification of Non Flexible Cables
        • 3 SELECTION OF WIRING ACCESSORIES
        • EARTHING OF ELECTRICAL INSTALLATIONS
          • 4 SAFETY REQUIREMENTS FOR ELECTRICAL WIRING WORKS IN RESIDENTIAL BUILDINGS
            • Why Electric Shocks Occur
            • INSTALLATION CIRCUITS AND SYSTEMS
            • Working Principal of Star-Delta Starter
            • Star-delta Starter Consists following units
            • Power Circuit of Star Delta Starter
            • Control Circuit of Star-Delta Starter (Open Transition)
            • What is Open or Closed Transition Starting
            • Effect of Transient in Starter (Open Transient starter)
            • Size of each part of Star-Delta starter
            • Motor Starting Characteristics of Star-Delta Starter
            • Advantages of Star-Delta starter
            • Disadvantages of Star-Delta starter
            • Features of star-delta starting
            • Application of Star-Delta Starter
            • LESSON 1 WIRING SYSTEM OF SINGLE PHASE DISTRIBUTION BOARD
            • LESSON 2 WIRING SYSTEM OF SINGLE PHASE LIGHTING CIRCUIT
            • LESSON 3ndash WIRING SYSTEM OF SINGLE PHASE POWER CIRCUIT
            • LESSON 4ndash CONDUIT BENDING AND TRUNKING FABRICATION TECHNIQUE
            • LESSON 5 ndashWIRING SYSTEM OF 1 Oslash LIGHTING AND POWER CIRCUIT
              • POWER CIRCUITS
                • LESSON 6 ndash WIRING SYSTEM OF 3 Oslash DISTRIBUTION BOARD
                • LESSON 7 ndash WIRING SYSTEM OF THREE PHASE LIGHTING AND POWER CIRCUIT
                • LESSON 8 INSPECTION AND TESTING OF ELECTRICAL INSTALLATION
                  • CONTINUITY TEST
                    • Polarity Test
                      • Earth Electrode Resistance Test
                      • Earth Electrode Resistance Measurement Method (Figure 86)
                        • Residual Current Device Test
                        • LESSON 9 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (DC)
                        • LESSON 10 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (AC)
                        • LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE
                        • LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
                          • LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
                          • LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
                          • LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
                            • a Dead circuit test
                            • b Life circuit test
                            • LESSON 16
                              • TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
                              • SELF-ASSESSMENT QUESTIONS
Page 64: WorksheetTask AMIN

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

  • ELECTRICITY SUPPLY SPECIFICATIONS
    • Legal Requirements
    • Determining Consumer Load Requirements
    • 2 CONTROL AND PROTECTION SYSTEM FOR ELECTRICAL WIRING
    • CABLE SELECTION
      • 32 Factors Related to Cable Current Carrying Capacity
      • Functions and Colour Identification of Non Flexible Cables
        • Conductor Insulation and Types of Wiring
        • Functions and Colour Identification of Non Flexible Cables
        • 3 SELECTION OF WIRING ACCESSORIES
        • EARTHING OF ELECTRICAL INSTALLATIONS
          • 4 SAFETY REQUIREMENTS FOR ELECTRICAL WIRING WORKS IN RESIDENTIAL BUILDINGS
            • Why Electric Shocks Occur
            • INSTALLATION CIRCUITS AND SYSTEMS
            • Working Principal of Star-Delta Starter
            • Star-delta Starter Consists following units
            • Power Circuit of Star Delta Starter
            • Control Circuit of Star-Delta Starter (Open Transition)
            • What is Open or Closed Transition Starting
            • Effect of Transient in Starter (Open Transient starter)
            • Size of each part of Star-Delta starter
            • Motor Starting Characteristics of Star-Delta Starter
            • Advantages of Star-Delta starter
            • Disadvantages of Star-Delta starter
            • Features of star-delta starting
            • Application of Star-Delta Starter
            • LESSON 1 WIRING SYSTEM OF SINGLE PHASE DISTRIBUTION BOARD
            • LESSON 2 WIRING SYSTEM OF SINGLE PHASE LIGHTING CIRCUIT
            • LESSON 3ndash WIRING SYSTEM OF SINGLE PHASE POWER CIRCUIT
            • LESSON 4ndash CONDUIT BENDING AND TRUNKING FABRICATION TECHNIQUE
            • LESSON 5 ndashWIRING SYSTEM OF 1 Oslash LIGHTING AND POWER CIRCUIT
              • POWER CIRCUITS
                • LESSON 6 ndash WIRING SYSTEM OF 3 Oslash DISTRIBUTION BOARD
                • LESSON 7 ndash WIRING SYSTEM OF THREE PHASE LIGHTING AND POWER CIRCUIT
                • LESSON 8 INSPECTION AND TESTING OF ELECTRICAL INSTALLATION
                  • CONTINUITY TEST
                    • Polarity Test
                      • Earth Electrode Resistance Test
                      • Earth Electrode Resistance Measurement Method (Figure 86)
                        • Residual Current Device Test
                        • LESSON 9 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (DC)
                        • LESSON 10 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (AC)
                        • LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE
                        • LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
                          • LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
                          • LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
                          • LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
                            • a Dead circuit test
                            • b Life circuit test
                            • LESSON 16
                              • TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
                              • SELF-ASSESSMENT QUESTIONS
Page 65: WorksheetTask AMIN

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

  • ELECTRICITY SUPPLY SPECIFICATIONS
    • Legal Requirements
    • Determining Consumer Load Requirements
    • 2 CONTROL AND PROTECTION SYSTEM FOR ELECTRICAL WIRING
    • CABLE SELECTION
      • 32 Factors Related to Cable Current Carrying Capacity
      • Functions and Colour Identification of Non Flexible Cables
        • Conductor Insulation and Types of Wiring
        • Functions and Colour Identification of Non Flexible Cables
        • 3 SELECTION OF WIRING ACCESSORIES
        • EARTHING OF ELECTRICAL INSTALLATIONS
          • 4 SAFETY REQUIREMENTS FOR ELECTRICAL WIRING WORKS IN RESIDENTIAL BUILDINGS
            • Why Electric Shocks Occur
            • INSTALLATION CIRCUITS AND SYSTEMS
            • Working Principal of Star-Delta Starter
            • Star-delta Starter Consists following units
            • Power Circuit of Star Delta Starter
            • Control Circuit of Star-Delta Starter (Open Transition)
            • What is Open or Closed Transition Starting
            • Effect of Transient in Starter (Open Transient starter)
            • Size of each part of Star-Delta starter
            • Motor Starting Characteristics of Star-Delta Starter
            • Advantages of Star-Delta starter
            • Disadvantages of Star-Delta starter
            • Features of star-delta starting
            • Application of Star-Delta Starter
            • LESSON 1 WIRING SYSTEM OF SINGLE PHASE DISTRIBUTION BOARD
            • LESSON 2 WIRING SYSTEM OF SINGLE PHASE LIGHTING CIRCUIT
            • LESSON 3ndash WIRING SYSTEM OF SINGLE PHASE POWER CIRCUIT
            • LESSON 4ndash CONDUIT BENDING AND TRUNKING FABRICATION TECHNIQUE
            • LESSON 5 ndashWIRING SYSTEM OF 1 Oslash LIGHTING AND POWER CIRCUIT
              • POWER CIRCUITS
                • LESSON 6 ndash WIRING SYSTEM OF 3 Oslash DISTRIBUTION BOARD
                • LESSON 7 ndash WIRING SYSTEM OF THREE PHASE LIGHTING AND POWER CIRCUIT
                • LESSON 8 INSPECTION AND TESTING OF ELECTRICAL INSTALLATION
                  • CONTINUITY TEST
                    • Polarity Test
                      • Earth Electrode Resistance Test
                      • Earth Electrode Resistance Measurement Method (Figure 86)
                        • Residual Current Device Test
                        • LESSON 9 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (DC)
                        • LESSON 10 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (AC)
                        • LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE
                        • LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
                          • LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
                          • LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
                          • LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
                            • a Dead circuit test
                            • b Life circuit test
                            • LESSON 16
                              • TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
                              • SELF-ASSESSMENT QUESTIONS
Page 66: WorksheetTask AMIN

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

  • ELECTRICITY SUPPLY SPECIFICATIONS
    • Legal Requirements
    • Determining Consumer Load Requirements
    • 2 CONTROL AND PROTECTION SYSTEM FOR ELECTRICAL WIRING
    • CABLE SELECTION
      • 32 Factors Related to Cable Current Carrying Capacity
      • Functions and Colour Identification of Non Flexible Cables
        • Conductor Insulation and Types of Wiring
        • Functions and Colour Identification of Non Flexible Cables
        • 3 SELECTION OF WIRING ACCESSORIES
        • EARTHING OF ELECTRICAL INSTALLATIONS
          • 4 SAFETY REQUIREMENTS FOR ELECTRICAL WIRING WORKS IN RESIDENTIAL BUILDINGS
            • Why Electric Shocks Occur
            • INSTALLATION CIRCUITS AND SYSTEMS
            • Working Principal of Star-Delta Starter
            • Star-delta Starter Consists following units
            • Power Circuit of Star Delta Starter
            • Control Circuit of Star-Delta Starter (Open Transition)
            • What is Open or Closed Transition Starting
            • Effect of Transient in Starter (Open Transient starter)
            • Size of each part of Star-Delta starter
            • Motor Starting Characteristics of Star-Delta Starter
            • Advantages of Star-Delta starter
            • Disadvantages of Star-Delta starter
            • Features of star-delta starting
            • Application of Star-Delta Starter
            • LESSON 1 WIRING SYSTEM OF SINGLE PHASE DISTRIBUTION BOARD
            • LESSON 2 WIRING SYSTEM OF SINGLE PHASE LIGHTING CIRCUIT
            • LESSON 3ndash WIRING SYSTEM OF SINGLE PHASE POWER CIRCUIT
            • LESSON 4ndash CONDUIT BENDING AND TRUNKING FABRICATION TECHNIQUE
            • LESSON 5 ndashWIRING SYSTEM OF 1 Oslash LIGHTING AND POWER CIRCUIT
              • POWER CIRCUITS
                • LESSON 6 ndash WIRING SYSTEM OF 3 Oslash DISTRIBUTION BOARD
                • LESSON 7 ndash WIRING SYSTEM OF THREE PHASE LIGHTING AND POWER CIRCUIT
                • LESSON 8 INSPECTION AND TESTING OF ELECTRICAL INSTALLATION
                  • CONTINUITY TEST
                    • Polarity Test
                      • Earth Electrode Resistance Test
                      • Earth Electrode Resistance Measurement Method (Figure 86)
                        • Residual Current Device Test
                        • LESSON 9 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (DC)
                        • LESSON 10 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (AC)
                        • LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE
                        • LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
                          • LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
                          • LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
                          • LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
                            • a Dead circuit test
                            • b Life circuit test
                            • LESSON 16
                              • TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
                              • SELF-ASSESSMENT QUESTIONS
Page 67: WorksheetTask AMIN

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

  • ELECTRICITY SUPPLY SPECIFICATIONS
    • Legal Requirements
    • Determining Consumer Load Requirements
    • 2 CONTROL AND PROTECTION SYSTEM FOR ELECTRICAL WIRING
    • CABLE SELECTION
      • 32 Factors Related to Cable Current Carrying Capacity
      • Functions and Colour Identification of Non Flexible Cables
        • Conductor Insulation and Types of Wiring
        • Functions and Colour Identification of Non Flexible Cables
        • 3 SELECTION OF WIRING ACCESSORIES
        • EARTHING OF ELECTRICAL INSTALLATIONS
          • 4 SAFETY REQUIREMENTS FOR ELECTRICAL WIRING WORKS IN RESIDENTIAL BUILDINGS
            • Why Electric Shocks Occur
            • INSTALLATION CIRCUITS AND SYSTEMS
            • Working Principal of Star-Delta Starter
            • Star-delta Starter Consists following units
            • Power Circuit of Star Delta Starter
            • Control Circuit of Star-Delta Starter (Open Transition)
            • What is Open or Closed Transition Starting
            • Effect of Transient in Starter (Open Transient starter)
            • Size of each part of Star-Delta starter
            • Motor Starting Characteristics of Star-Delta Starter
            • Advantages of Star-Delta starter
            • Disadvantages of Star-Delta starter
            • Features of star-delta starting
            • Application of Star-Delta Starter
            • LESSON 1 WIRING SYSTEM OF SINGLE PHASE DISTRIBUTION BOARD
            • LESSON 2 WIRING SYSTEM OF SINGLE PHASE LIGHTING CIRCUIT
            • LESSON 3ndash WIRING SYSTEM OF SINGLE PHASE POWER CIRCUIT
            • LESSON 4ndash CONDUIT BENDING AND TRUNKING FABRICATION TECHNIQUE
            • LESSON 5 ndashWIRING SYSTEM OF 1 Oslash LIGHTING AND POWER CIRCUIT
              • POWER CIRCUITS
                • LESSON 6 ndash WIRING SYSTEM OF 3 Oslash DISTRIBUTION BOARD
                • LESSON 7 ndash WIRING SYSTEM OF THREE PHASE LIGHTING AND POWER CIRCUIT
                • LESSON 8 INSPECTION AND TESTING OF ELECTRICAL INSTALLATION
                  • CONTINUITY TEST
                    • Polarity Test
                      • Earth Electrode Resistance Test
                      • Earth Electrode Resistance Measurement Method (Figure 86)
                        • Residual Current Device Test
                        • LESSON 9 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (DC)
                        • LESSON 10 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (AC)
                        • LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE
                        • LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
                          • LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
                          • LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
                          • LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
                            • a Dead circuit test
                            • b Life circuit test
                            • LESSON 16
                              • TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
                              • SELF-ASSESSMENT QUESTIONS
Page 68: WorksheetTask AMIN

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

  • ELECTRICITY SUPPLY SPECIFICATIONS
    • Legal Requirements
    • Determining Consumer Load Requirements
    • 2 CONTROL AND PROTECTION SYSTEM FOR ELECTRICAL WIRING
    • CABLE SELECTION
      • 32 Factors Related to Cable Current Carrying Capacity
      • Functions and Colour Identification of Non Flexible Cables
        • Conductor Insulation and Types of Wiring
        • Functions and Colour Identification of Non Flexible Cables
        • 3 SELECTION OF WIRING ACCESSORIES
        • EARTHING OF ELECTRICAL INSTALLATIONS
          • 4 SAFETY REQUIREMENTS FOR ELECTRICAL WIRING WORKS IN RESIDENTIAL BUILDINGS
            • Why Electric Shocks Occur
            • INSTALLATION CIRCUITS AND SYSTEMS
            • Working Principal of Star-Delta Starter
            • Star-delta Starter Consists following units
            • Power Circuit of Star Delta Starter
            • Control Circuit of Star-Delta Starter (Open Transition)
            • What is Open or Closed Transition Starting
            • Effect of Transient in Starter (Open Transient starter)
            • Size of each part of Star-Delta starter
            • Motor Starting Characteristics of Star-Delta Starter
            • Advantages of Star-Delta starter
            • Disadvantages of Star-Delta starter
            • Features of star-delta starting
            • Application of Star-Delta Starter
            • LESSON 1 WIRING SYSTEM OF SINGLE PHASE DISTRIBUTION BOARD
            • LESSON 2 WIRING SYSTEM OF SINGLE PHASE LIGHTING CIRCUIT
            • LESSON 3ndash WIRING SYSTEM OF SINGLE PHASE POWER CIRCUIT
            • LESSON 4ndash CONDUIT BENDING AND TRUNKING FABRICATION TECHNIQUE
            • LESSON 5 ndashWIRING SYSTEM OF 1 Oslash LIGHTING AND POWER CIRCUIT
              • POWER CIRCUITS
                • LESSON 6 ndash WIRING SYSTEM OF 3 Oslash DISTRIBUTION BOARD
                • LESSON 7 ndash WIRING SYSTEM OF THREE PHASE LIGHTING AND POWER CIRCUIT
                • LESSON 8 INSPECTION AND TESTING OF ELECTRICAL INSTALLATION
                  • CONTINUITY TEST
                    • Polarity Test
                      • Earth Electrode Resistance Test
                      • Earth Electrode Resistance Measurement Method (Figure 86)
                        • Residual Current Device Test
                        • LESSON 9 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (DC)
                        • LESSON 10 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (AC)
                        • LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE
                        • LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
                          • LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
                          • LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
                          • LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
                            • a Dead circuit test
                            • b Life circuit test
                            • LESSON 16
                              • TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
                              • SELF-ASSESSMENT QUESTIONS
Page 69: WorksheetTask AMIN

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

  • ELECTRICITY SUPPLY SPECIFICATIONS
    • Legal Requirements
    • Determining Consumer Load Requirements
    • 2 CONTROL AND PROTECTION SYSTEM FOR ELECTRICAL WIRING
    • CABLE SELECTION
      • 32 Factors Related to Cable Current Carrying Capacity
      • Functions and Colour Identification of Non Flexible Cables
        • Conductor Insulation and Types of Wiring
        • Functions and Colour Identification of Non Flexible Cables
        • 3 SELECTION OF WIRING ACCESSORIES
        • EARTHING OF ELECTRICAL INSTALLATIONS
          • 4 SAFETY REQUIREMENTS FOR ELECTRICAL WIRING WORKS IN RESIDENTIAL BUILDINGS
            • Why Electric Shocks Occur
            • INSTALLATION CIRCUITS AND SYSTEMS
            • Working Principal of Star-Delta Starter
            • Star-delta Starter Consists following units
            • Power Circuit of Star Delta Starter
            • Control Circuit of Star-Delta Starter (Open Transition)
            • What is Open or Closed Transition Starting
            • Effect of Transient in Starter (Open Transient starter)
            • Size of each part of Star-Delta starter
            • Motor Starting Characteristics of Star-Delta Starter
            • Advantages of Star-Delta starter
            • Disadvantages of Star-Delta starter
            • Features of star-delta starting
            • Application of Star-Delta Starter
            • LESSON 1 WIRING SYSTEM OF SINGLE PHASE DISTRIBUTION BOARD
            • LESSON 2 WIRING SYSTEM OF SINGLE PHASE LIGHTING CIRCUIT
            • LESSON 3ndash WIRING SYSTEM OF SINGLE PHASE POWER CIRCUIT
            • LESSON 4ndash CONDUIT BENDING AND TRUNKING FABRICATION TECHNIQUE
            • LESSON 5 ndashWIRING SYSTEM OF 1 Oslash LIGHTING AND POWER CIRCUIT
              • POWER CIRCUITS
                • LESSON 6 ndash WIRING SYSTEM OF 3 Oslash DISTRIBUTION BOARD
                • LESSON 7 ndash WIRING SYSTEM OF THREE PHASE LIGHTING AND POWER CIRCUIT
                • LESSON 8 INSPECTION AND TESTING OF ELECTRICAL INSTALLATION
                  • CONTINUITY TEST
                    • Polarity Test
                      • Earth Electrode Resistance Test
                      • Earth Electrode Resistance Measurement Method (Figure 86)
                        • Residual Current Device Test
                        • LESSON 9 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (DC)
                        • LESSON 10 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (AC)
                        • LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE
                        • LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
                          • LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
                          • LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
                          • LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
                            • a Dead circuit test
                            • b Life circuit test
                            • LESSON 16
                              • TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
                              • SELF-ASSESSMENT QUESTIONS
Page 70: WorksheetTask AMIN

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

  • ELECTRICITY SUPPLY SPECIFICATIONS
    • Legal Requirements
    • Determining Consumer Load Requirements
    • 2 CONTROL AND PROTECTION SYSTEM FOR ELECTRICAL WIRING
    • CABLE SELECTION
      • 32 Factors Related to Cable Current Carrying Capacity
      • Functions and Colour Identification of Non Flexible Cables
        • Conductor Insulation and Types of Wiring
        • Functions and Colour Identification of Non Flexible Cables
        • 3 SELECTION OF WIRING ACCESSORIES
        • EARTHING OF ELECTRICAL INSTALLATIONS
          • 4 SAFETY REQUIREMENTS FOR ELECTRICAL WIRING WORKS IN RESIDENTIAL BUILDINGS
            • Why Electric Shocks Occur
            • INSTALLATION CIRCUITS AND SYSTEMS
            • Working Principal of Star-Delta Starter
            • Star-delta Starter Consists following units
            • Power Circuit of Star Delta Starter
            • Control Circuit of Star-Delta Starter (Open Transition)
            • What is Open or Closed Transition Starting
            • Effect of Transient in Starter (Open Transient starter)
            • Size of each part of Star-Delta starter
            • Motor Starting Characteristics of Star-Delta Starter
            • Advantages of Star-Delta starter
            • Disadvantages of Star-Delta starter
            • Features of star-delta starting
            • Application of Star-Delta Starter
            • LESSON 1 WIRING SYSTEM OF SINGLE PHASE DISTRIBUTION BOARD
            • LESSON 2 WIRING SYSTEM OF SINGLE PHASE LIGHTING CIRCUIT
            • LESSON 3ndash WIRING SYSTEM OF SINGLE PHASE POWER CIRCUIT
            • LESSON 4ndash CONDUIT BENDING AND TRUNKING FABRICATION TECHNIQUE
            • LESSON 5 ndashWIRING SYSTEM OF 1 Oslash LIGHTING AND POWER CIRCUIT
              • POWER CIRCUITS
                • LESSON 6 ndash WIRING SYSTEM OF 3 Oslash DISTRIBUTION BOARD
                • LESSON 7 ndash WIRING SYSTEM OF THREE PHASE LIGHTING AND POWER CIRCUIT
                • LESSON 8 INSPECTION AND TESTING OF ELECTRICAL INSTALLATION
                  • CONTINUITY TEST
                    • Polarity Test
                      • Earth Electrode Resistance Test
                      • Earth Electrode Resistance Measurement Method (Figure 86)
                        • Residual Current Device Test
                        • LESSON 9 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (DC)
                        • LESSON 10 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (AC)
                        • LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE
                        • LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
                          • LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
                          • LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
                          • LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
                            • a Dead circuit test
                            • b Life circuit test
                            • LESSON 16
                              • TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
                              • SELF-ASSESSMENT QUESTIONS
Page 71: WorksheetTask AMIN

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

  • ELECTRICITY SUPPLY SPECIFICATIONS
    • Legal Requirements
    • Determining Consumer Load Requirements
    • 2 CONTROL AND PROTECTION SYSTEM FOR ELECTRICAL WIRING
    • CABLE SELECTION
      • 32 Factors Related to Cable Current Carrying Capacity
      • Functions and Colour Identification of Non Flexible Cables
        • Conductor Insulation and Types of Wiring
        • Functions and Colour Identification of Non Flexible Cables
        • 3 SELECTION OF WIRING ACCESSORIES
        • EARTHING OF ELECTRICAL INSTALLATIONS
          • 4 SAFETY REQUIREMENTS FOR ELECTRICAL WIRING WORKS IN RESIDENTIAL BUILDINGS
            • Why Electric Shocks Occur
            • INSTALLATION CIRCUITS AND SYSTEMS
            • Working Principal of Star-Delta Starter
            • Star-delta Starter Consists following units
            • Power Circuit of Star Delta Starter
            • Control Circuit of Star-Delta Starter (Open Transition)
            • What is Open or Closed Transition Starting
            • Effect of Transient in Starter (Open Transient starter)
            • Size of each part of Star-Delta starter
            • Motor Starting Characteristics of Star-Delta Starter
            • Advantages of Star-Delta starter
            • Disadvantages of Star-Delta starter
            • Features of star-delta starting
            • Application of Star-Delta Starter
            • LESSON 1 WIRING SYSTEM OF SINGLE PHASE DISTRIBUTION BOARD
            • LESSON 2 WIRING SYSTEM OF SINGLE PHASE LIGHTING CIRCUIT
            • LESSON 3ndash WIRING SYSTEM OF SINGLE PHASE POWER CIRCUIT
            • LESSON 4ndash CONDUIT BENDING AND TRUNKING FABRICATION TECHNIQUE
            • LESSON 5 ndashWIRING SYSTEM OF 1 Oslash LIGHTING AND POWER CIRCUIT
              • POWER CIRCUITS
                • LESSON 6 ndash WIRING SYSTEM OF 3 Oslash DISTRIBUTION BOARD
                • LESSON 7 ndash WIRING SYSTEM OF THREE PHASE LIGHTING AND POWER CIRCUIT
                • LESSON 8 INSPECTION AND TESTING OF ELECTRICAL INSTALLATION
                  • CONTINUITY TEST
                    • Polarity Test
                      • Earth Electrode Resistance Test
                      • Earth Electrode Resistance Measurement Method (Figure 86)
                        • Residual Current Device Test
                        • LESSON 9 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (DC)
                        • LESSON 10 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (AC)
                        • LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE
                        • LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
                          • LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
                          • LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
                          • LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
                            • a Dead circuit test
                            • b Life circuit test
                            • LESSON 16
                              • TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
                              • SELF-ASSESSMENT QUESTIONS
Page 72: WorksheetTask AMIN

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

  • ELECTRICITY SUPPLY SPECIFICATIONS
    • Legal Requirements
    • Determining Consumer Load Requirements
    • 2 CONTROL AND PROTECTION SYSTEM FOR ELECTRICAL WIRING
    • CABLE SELECTION
      • 32 Factors Related to Cable Current Carrying Capacity
      • Functions and Colour Identification of Non Flexible Cables
        • Conductor Insulation and Types of Wiring
        • Functions and Colour Identification of Non Flexible Cables
        • 3 SELECTION OF WIRING ACCESSORIES
        • EARTHING OF ELECTRICAL INSTALLATIONS
          • 4 SAFETY REQUIREMENTS FOR ELECTRICAL WIRING WORKS IN RESIDENTIAL BUILDINGS
            • Why Electric Shocks Occur
            • INSTALLATION CIRCUITS AND SYSTEMS
            • Working Principal of Star-Delta Starter
            • Star-delta Starter Consists following units
            • Power Circuit of Star Delta Starter
            • Control Circuit of Star-Delta Starter (Open Transition)
            • What is Open or Closed Transition Starting
            • Effect of Transient in Starter (Open Transient starter)
            • Size of each part of Star-Delta starter
            • Motor Starting Characteristics of Star-Delta Starter
            • Advantages of Star-Delta starter
            • Disadvantages of Star-Delta starter
            • Features of star-delta starting
            • Application of Star-Delta Starter
            • LESSON 1 WIRING SYSTEM OF SINGLE PHASE DISTRIBUTION BOARD
            • LESSON 2 WIRING SYSTEM OF SINGLE PHASE LIGHTING CIRCUIT
            • LESSON 3ndash WIRING SYSTEM OF SINGLE PHASE POWER CIRCUIT
            • LESSON 4ndash CONDUIT BENDING AND TRUNKING FABRICATION TECHNIQUE
            • LESSON 5 ndashWIRING SYSTEM OF 1 Oslash LIGHTING AND POWER CIRCUIT
              • POWER CIRCUITS
                • LESSON 6 ndash WIRING SYSTEM OF 3 Oslash DISTRIBUTION BOARD
                • LESSON 7 ndash WIRING SYSTEM OF THREE PHASE LIGHTING AND POWER CIRCUIT
                • LESSON 8 INSPECTION AND TESTING OF ELECTRICAL INSTALLATION
                  • CONTINUITY TEST
                    • Polarity Test
                      • Earth Electrode Resistance Test
                      • Earth Electrode Resistance Measurement Method (Figure 86)
                        • Residual Current Device Test
                        • LESSON 9 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (DC)
                        • LESSON 10 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (AC)
                        • LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE
                        • LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
                          • LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
                          • LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
                          • LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
                            • a Dead circuit test
                            • b Life circuit test
                            • LESSON 16
                              • TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
                              • SELF-ASSESSMENT QUESTIONS
Page 73: WorksheetTask AMIN

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

  • ELECTRICITY SUPPLY SPECIFICATIONS
    • Legal Requirements
    • Determining Consumer Load Requirements
    • 2 CONTROL AND PROTECTION SYSTEM FOR ELECTRICAL WIRING
    • CABLE SELECTION
      • 32 Factors Related to Cable Current Carrying Capacity
      • Functions and Colour Identification of Non Flexible Cables
        • Conductor Insulation and Types of Wiring
        • Functions and Colour Identification of Non Flexible Cables
        • 3 SELECTION OF WIRING ACCESSORIES
        • EARTHING OF ELECTRICAL INSTALLATIONS
          • 4 SAFETY REQUIREMENTS FOR ELECTRICAL WIRING WORKS IN RESIDENTIAL BUILDINGS
            • Why Electric Shocks Occur
            • INSTALLATION CIRCUITS AND SYSTEMS
            • Working Principal of Star-Delta Starter
            • Star-delta Starter Consists following units
            • Power Circuit of Star Delta Starter
            • Control Circuit of Star-Delta Starter (Open Transition)
            • What is Open or Closed Transition Starting
            • Effect of Transient in Starter (Open Transient starter)
            • Size of each part of Star-Delta starter
            • Motor Starting Characteristics of Star-Delta Starter
            • Advantages of Star-Delta starter
            • Disadvantages of Star-Delta starter
            • Features of star-delta starting
            • Application of Star-Delta Starter
            • LESSON 1 WIRING SYSTEM OF SINGLE PHASE DISTRIBUTION BOARD
            • LESSON 2 WIRING SYSTEM OF SINGLE PHASE LIGHTING CIRCUIT
            • LESSON 3ndash WIRING SYSTEM OF SINGLE PHASE POWER CIRCUIT
            • LESSON 4ndash CONDUIT BENDING AND TRUNKING FABRICATION TECHNIQUE
            • LESSON 5 ndashWIRING SYSTEM OF 1 Oslash LIGHTING AND POWER CIRCUIT
              • POWER CIRCUITS
                • LESSON 6 ndash WIRING SYSTEM OF 3 Oslash DISTRIBUTION BOARD
                • LESSON 7 ndash WIRING SYSTEM OF THREE PHASE LIGHTING AND POWER CIRCUIT
                • LESSON 8 INSPECTION AND TESTING OF ELECTRICAL INSTALLATION
                  • CONTINUITY TEST
                    • Polarity Test
                      • Earth Electrode Resistance Test
                      • Earth Electrode Resistance Measurement Method (Figure 86)
                        • Residual Current Device Test
                        • LESSON 9 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (DC)
                        • LESSON 10 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (AC)
                        • LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE
                        • LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
                          • LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
                          • LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
                          • LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
                            • a Dead circuit test
                            • b Life circuit test
                            • LESSON 16
                              • TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
                              • SELF-ASSESSMENT QUESTIONS
Page 74: WorksheetTask AMIN

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

  • ELECTRICITY SUPPLY SPECIFICATIONS
    • Legal Requirements
    • Determining Consumer Load Requirements
    • 2 CONTROL AND PROTECTION SYSTEM FOR ELECTRICAL WIRING
    • CABLE SELECTION
      • 32 Factors Related to Cable Current Carrying Capacity
      • Functions and Colour Identification of Non Flexible Cables
        • Conductor Insulation and Types of Wiring
        • Functions and Colour Identification of Non Flexible Cables
        • 3 SELECTION OF WIRING ACCESSORIES
        • EARTHING OF ELECTRICAL INSTALLATIONS
          • 4 SAFETY REQUIREMENTS FOR ELECTRICAL WIRING WORKS IN RESIDENTIAL BUILDINGS
            • Why Electric Shocks Occur
            • INSTALLATION CIRCUITS AND SYSTEMS
            • Working Principal of Star-Delta Starter
            • Star-delta Starter Consists following units
            • Power Circuit of Star Delta Starter
            • Control Circuit of Star-Delta Starter (Open Transition)
            • What is Open or Closed Transition Starting
            • Effect of Transient in Starter (Open Transient starter)
            • Size of each part of Star-Delta starter
            • Motor Starting Characteristics of Star-Delta Starter
            • Advantages of Star-Delta starter
            • Disadvantages of Star-Delta starter
            • Features of star-delta starting
            • Application of Star-Delta Starter
            • LESSON 1 WIRING SYSTEM OF SINGLE PHASE DISTRIBUTION BOARD
            • LESSON 2 WIRING SYSTEM OF SINGLE PHASE LIGHTING CIRCUIT
            • LESSON 3ndash WIRING SYSTEM OF SINGLE PHASE POWER CIRCUIT
            • LESSON 4ndash CONDUIT BENDING AND TRUNKING FABRICATION TECHNIQUE
            • LESSON 5 ndashWIRING SYSTEM OF 1 Oslash LIGHTING AND POWER CIRCUIT
              • POWER CIRCUITS
                • LESSON 6 ndash WIRING SYSTEM OF 3 Oslash DISTRIBUTION BOARD
                • LESSON 7 ndash WIRING SYSTEM OF THREE PHASE LIGHTING AND POWER CIRCUIT
                • LESSON 8 INSPECTION AND TESTING OF ELECTRICAL INSTALLATION
                  • CONTINUITY TEST
                    • Polarity Test
                      • Earth Electrode Resistance Test
                      • Earth Electrode Resistance Measurement Method (Figure 86)
                        • Residual Current Device Test
                        • LESSON 9 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (DC)
                        • LESSON 10 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (AC)
                        • LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE
                        • LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
                          • LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
                          • LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
                          • LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
                            • a Dead circuit test
                            • b Life circuit test
                            • LESSON 16
                              • TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
                              • SELF-ASSESSMENT QUESTIONS
Page 75: WorksheetTask AMIN

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

  • ELECTRICITY SUPPLY SPECIFICATIONS
    • Legal Requirements
    • Determining Consumer Load Requirements
    • 2 CONTROL AND PROTECTION SYSTEM FOR ELECTRICAL WIRING
    • CABLE SELECTION
      • 32 Factors Related to Cable Current Carrying Capacity
      • Functions and Colour Identification of Non Flexible Cables
        • Conductor Insulation and Types of Wiring
        • Functions and Colour Identification of Non Flexible Cables
        • 3 SELECTION OF WIRING ACCESSORIES
        • EARTHING OF ELECTRICAL INSTALLATIONS
          • 4 SAFETY REQUIREMENTS FOR ELECTRICAL WIRING WORKS IN RESIDENTIAL BUILDINGS
            • Why Electric Shocks Occur
            • INSTALLATION CIRCUITS AND SYSTEMS
            • Working Principal of Star-Delta Starter
            • Star-delta Starter Consists following units
            • Power Circuit of Star Delta Starter
            • Control Circuit of Star-Delta Starter (Open Transition)
            • What is Open or Closed Transition Starting
            • Effect of Transient in Starter (Open Transient starter)
            • Size of each part of Star-Delta starter
            • Motor Starting Characteristics of Star-Delta Starter
            • Advantages of Star-Delta starter
            • Disadvantages of Star-Delta starter
            • Features of star-delta starting
            • Application of Star-Delta Starter
            • LESSON 1 WIRING SYSTEM OF SINGLE PHASE DISTRIBUTION BOARD
            • LESSON 2 WIRING SYSTEM OF SINGLE PHASE LIGHTING CIRCUIT
            • LESSON 3ndash WIRING SYSTEM OF SINGLE PHASE POWER CIRCUIT
            • LESSON 4ndash CONDUIT BENDING AND TRUNKING FABRICATION TECHNIQUE
            • LESSON 5 ndashWIRING SYSTEM OF 1 Oslash LIGHTING AND POWER CIRCUIT
              • POWER CIRCUITS
                • LESSON 6 ndash WIRING SYSTEM OF 3 Oslash DISTRIBUTION BOARD
                • LESSON 7 ndash WIRING SYSTEM OF THREE PHASE LIGHTING AND POWER CIRCUIT
                • LESSON 8 INSPECTION AND TESTING OF ELECTRICAL INSTALLATION
                  • CONTINUITY TEST
                    • Polarity Test
                      • Earth Electrode Resistance Test
                      • Earth Electrode Resistance Measurement Method (Figure 86)
                        • Residual Current Device Test
                        • LESSON 9 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (DC)
                        • LESSON 10 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (AC)
                        • LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE
                        • LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
                          • LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
                          • LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
                          • LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
                            • a Dead circuit test
                            • b Life circuit test
                            • LESSON 16
                              • TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
                              • SELF-ASSESSMENT QUESTIONS
Page 76: WorksheetTask AMIN

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

  • ELECTRICITY SUPPLY SPECIFICATIONS
    • Legal Requirements
    • Determining Consumer Load Requirements
    • 2 CONTROL AND PROTECTION SYSTEM FOR ELECTRICAL WIRING
    • CABLE SELECTION
      • 32 Factors Related to Cable Current Carrying Capacity
      • Functions and Colour Identification of Non Flexible Cables
        • Conductor Insulation and Types of Wiring
        • Functions and Colour Identification of Non Flexible Cables
        • 3 SELECTION OF WIRING ACCESSORIES
        • EARTHING OF ELECTRICAL INSTALLATIONS
          • 4 SAFETY REQUIREMENTS FOR ELECTRICAL WIRING WORKS IN RESIDENTIAL BUILDINGS
            • Why Electric Shocks Occur
            • INSTALLATION CIRCUITS AND SYSTEMS
            • Working Principal of Star-Delta Starter
            • Star-delta Starter Consists following units
            • Power Circuit of Star Delta Starter
            • Control Circuit of Star-Delta Starter (Open Transition)
            • What is Open or Closed Transition Starting
            • Effect of Transient in Starter (Open Transient starter)
            • Size of each part of Star-Delta starter
            • Motor Starting Characteristics of Star-Delta Starter
            • Advantages of Star-Delta starter
            • Disadvantages of Star-Delta starter
            • Features of star-delta starting
            • Application of Star-Delta Starter
            • LESSON 1 WIRING SYSTEM OF SINGLE PHASE DISTRIBUTION BOARD
            • LESSON 2 WIRING SYSTEM OF SINGLE PHASE LIGHTING CIRCUIT
            • LESSON 3ndash WIRING SYSTEM OF SINGLE PHASE POWER CIRCUIT
            • LESSON 4ndash CONDUIT BENDING AND TRUNKING FABRICATION TECHNIQUE
            • LESSON 5 ndashWIRING SYSTEM OF 1 Oslash LIGHTING AND POWER CIRCUIT
              • POWER CIRCUITS
                • LESSON 6 ndash WIRING SYSTEM OF 3 Oslash DISTRIBUTION BOARD
                • LESSON 7 ndash WIRING SYSTEM OF THREE PHASE LIGHTING AND POWER CIRCUIT
                • LESSON 8 INSPECTION AND TESTING OF ELECTRICAL INSTALLATION
                  • CONTINUITY TEST
                    • Polarity Test
                      • Earth Electrode Resistance Test
                      • Earth Electrode Resistance Measurement Method (Figure 86)
                        • Residual Current Device Test
                        • LESSON 9 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (DC)
                        • LESSON 10 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (AC)
                        • LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE
                        • LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
                          • LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
                          • LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
                          • LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
                            • a Dead circuit test
                            • b Life circuit test
                            • LESSON 16
                              • TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
                              • SELF-ASSESSMENT QUESTIONS
Page 77: WorksheetTask AMIN

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

  • ELECTRICITY SUPPLY SPECIFICATIONS
    • Legal Requirements
    • Determining Consumer Load Requirements
    • 2 CONTROL AND PROTECTION SYSTEM FOR ELECTRICAL WIRING
    • CABLE SELECTION
      • 32 Factors Related to Cable Current Carrying Capacity
      • Functions and Colour Identification of Non Flexible Cables
        • Conductor Insulation and Types of Wiring
        • Functions and Colour Identification of Non Flexible Cables
        • 3 SELECTION OF WIRING ACCESSORIES
        • EARTHING OF ELECTRICAL INSTALLATIONS
          • 4 SAFETY REQUIREMENTS FOR ELECTRICAL WIRING WORKS IN RESIDENTIAL BUILDINGS
            • Why Electric Shocks Occur
            • INSTALLATION CIRCUITS AND SYSTEMS
            • Working Principal of Star-Delta Starter
            • Star-delta Starter Consists following units
            • Power Circuit of Star Delta Starter
            • Control Circuit of Star-Delta Starter (Open Transition)
            • What is Open or Closed Transition Starting
            • Effect of Transient in Starter (Open Transient starter)
            • Size of each part of Star-Delta starter
            • Motor Starting Characteristics of Star-Delta Starter
            • Advantages of Star-Delta starter
            • Disadvantages of Star-Delta starter
            • Features of star-delta starting
            • Application of Star-Delta Starter
            • LESSON 1 WIRING SYSTEM OF SINGLE PHASE DISTRIBUTION BOARD
            • LESSON 2 WIRING SYSTEM OF SINGLE PHASE LIGHTING CIRCUIT
            • LESSON 3ndash WIRING SYSTEM OF SINGLE PHASE POWER CIRCUIT
            • LESSON 4ndash CONDUIT BENDING AND TRUNKING FABRICATION TECHNIQUE
            • LESSON 5 ndashWIRING SYSTEM OF 1 Oslash LIGHTING AND POWER CIRCUIT
              • POWER CIRCUITS
                • LESSON 6 ndash WIRING SYSTEM OF 3 Oslash DISTRIBUTION BOARD
                • LESSON 7 ndash WIRING SYSTEM OF THREE PHASE LIGHTING AND POWER CIRCUIT
                • LESSON 8 INSPECTION AND TESTING OF ELECTRICAL INSTALLATION
                  • CONTINUITY TEST
                    • Polarity Test
                      • Earth Electrode Resistance Test
                      • Earth Electrode Resistance Measurement Method (Figure 86)
                        • Residual Current Device Test
                        • LESSON 9 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (DC)
                        • LESSON 10 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (AC)
                        • LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE
                        • LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
                          • LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
                          • LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
                          • LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
                            • a Dead circuit test
                            • b Life circuit test
                            • LESSON 16
                              • TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
                              • SELF-ASSESSMENT QUESTIONS
Page 78: WorksheetTask AMIN

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

  • ELECTRICITY SUPPLY SPECIFICATIONS
    • Legal Requirements
    • Determining Consumer Load Requirements
    • 2 CONTROL AND PROTECTION SYSTEM FOR ELECTRICAL WIRING
    • CABLE SELECTION
      • 32 Factors Related to Cable Current Carrying Capacity
      • Functions and Colour Identification of Non Flexible Cables
        • Conductor Insulation and Types of Wiring
        • Functions and Colour Identification of Non Flexible Cables
        • 3 SELECTION OF WIRING ACCESSORIES
        • EARTHING OF ELECTRICAL INSTALLATIONS
          • 4 SAFETY REQUIREMENTS FOR ELECTRICAL WIRING WORKS IN RESIDENTIAL BUILDINGS
            • Why Electric Shocks Occur
            • INSTALLATION CIRCUITS AND SYSTEMS
            • Working Principal of Star-Delta Starter
            • Star-delta Starter Consists following units
            • Power Circuit of Star Delta Starter
            • Control Circuit of Star-Delta Starter (Open Transition)
            • What is Open or Closed Transition Starting
            • Effect of Transient in Starter (Open Transient starter)
            • Size of each part of Star-Delta starter
            • Motor Starting Characteristics of Star-Delta Starter
            • Advantages of Star-Delta starter
            • Disadvantages of Star-Delta starter
            • Features of star-delta starting
            • Application of Star-Delta Starter
            • LESSON 1 WIRING SYSTEM OF SINGLE PHASE DISTRIBUTION BOARD
            • LESSON 2 WIRING SYSTEM OF SINGLE PHASE LIGHTING CIRCUIT
            • LESSON 3ndash WIRING SYSTEM OF SINGLE PHASE POWER CIRCUIT
            • LESSON 4ndash CONDUIT BENDING AND TRUNKING FABRICATION TECHNIQUE
            • LESSON 5 ndashWIRING SYSTEM OF 1 Oslash LIGHTING AND POWER CIRCUIT
              • POWER CIRCUITS
                • LESSON 6 ndash WIRING SYSTEM OF 3 Oslash DISTRIBUTION BOARD
                • LESSON 7 ndash WIRING SYSTEM OF THREE PHASE LIGHTING AND POWER CIRCUIT
                • LESSON 8 INSPECTION AND TESTING OF ELECTRICAL INSTALLATION
                  • CONTINUITY TEST
                    • Polarity Test
                      • Earth Electrode Resistance Test
                      • Earth Electrode Resistance Measurement Method (Figure 86)
                        • Residual Current Device Test
                        • LESSON 9 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (DC)
                        • LESSON 10 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (AC)
                        • LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE
                        • LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
                          • LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
                          • LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
                          • LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
                            • a Dead circuit test
                            • b Life circuit test
                            • LESSON 16
                              • TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
                              • SELF-ASSESSMENT QUESTIONS
Page 79: WorksheetTask AMIN

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

  • ELECTRICITY SUPPLY SPECIFICATIONS
    • Legal Requirements
    • Determining Consumer Load Requirements
    • 2 CONTROL AND PROTECTION SYSTEM FOR ELECTRICAL WIRING
    • CABLE SELECTION
      • 32 Factors Related to Cable Current Carrying Capacity
      • Functions and Colour Identification of Non Flexible Cables
        • Conductor Insulation and Types of Wiring
        • Functions and Colour Identification of Non Flexible Cables
        • 3 SELECTION OF WIRING ACCESSORIES
        • EARTHING OF ELECTRICAL INSTALLATIONS
          • 4 SAFETY REQUIREMENTS FOR ELECTRICAL WIRING WORKS IN RESIDENTIAL BUILDINGS
            • Why Electric Shocks Occur
            • INSTALLATION CIRCUITS AND SYSTEMS
            • Working Principal of Star-Delta Starter
            • Star-delta Starter Consists following units
            • Power Circuit of Star Delta Starter
            • Control Circuit of Star-Delta Starter (Open Transition)
            • What is Open or Closed Transition Starting
            • Effect of Transient in Starter (Open Transient starter)
            • Size of each part of Star-Delta starter
            • Motor Starting Characteristics of Star-Delta Starter
            • Advantages of Star-Delta starter
            • Disadvantages of Star-Delta starter
            • Features of star-delta starting
            • Application of Star-Delta Starter
            • LESSON 1 WIRING SYSTEM OF SINGLE PHASE DISTRIBUTION BOARD
            • LESSON 2 WIRING SYSTEM OF SINGLE PHASE LIGHTING CIRCUIT
            • LESSON 3ndash WIRING SYSTEM OF SINGLE PHASE POWER CIRCUIT
            • LESSON 4ndash CONDUIT BENDING AND TRUNKING FABRICATION TECHNIQUE
            • LESSON 5 ndashWIRING SYSTEM OF 1 Oslash LIGHTING AND POWER CIRCUIT
              • POWER CIRCUITS
                • LESSON 6 ndash WIRING SYSTEM OF 3 Oslash DISTRIBUTION BOARD
                • LESSON 7 ndash WIRING SYSTEM OF THREE PHASE LIGHTING AND POWER CIRCUIT
                • LESSON 8 INSPECTION AND TESTING OF ELECTRICAL INSTALLATION
                  • CONTINUITY TEST
                    • Polarity Test
                      • Earth Electrode Resistance Test
                      • Earth Electrode Resistance Measurement Method (Figure 86)
                        • Residual Current Device Test
                        • LESSON 9 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (DC)
                        • LESSON 10 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (AC)
                        • LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE
                        • LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
                          • LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
                          • LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
                          • LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
                            • a Dead circuit test
                            • b Life circuit test
                            • LESSON 16
                              • TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
                              • SELF-ASSESSMENT QUESTIONS
Page 80: WorksheetTask AMIN

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

  • ELECTRICITY SUPPLY SPECIFICATIONS
    • Legal Requirements
    • Determining Consumer Load Requirements
    • 2 CONTROL AND PROTECTION SYSTEM FOR ELECTRICAL WIRING
    • CABLE SELECTION
      • 32 Factors Related to Cable Current Carrying Capacity
      • Functions and Colour Identification of Non Flexible Cables
        • Conductor Insulation and Types of Wiring
        • Functions and Colour Identification of Non Flexible Cables
        • 3 SELECTION OF WIRING ACCESSORIES
        • EARTHING OF ELECTRICAL INSTALLATIONS
          • 4 SAFETY REQUIREMENTS FOR ELECTRICAL WIRING WORKS IN RESIDENTIAL BUILDINGS
            • Why Electric Shocks Occur
            • INSTALLATION CIRCUITS AND SYSTEMS
            • Working Principal of Star-Delta Starter
            • Star-delta Starter Consists following units
            • Power Circuit of Star Delta Starter
            • Control Circuit of Star-Delta Starter (Open Transition)
            • What is Open or Closed Transition Starting
            • Effect of Transient in Starter (Open Transient starter)
            • Size of each part of Star-Delta starter
            • Motor Starting Characteristics of Star-Delta Starter
            • Advantages of Star-Delta starter
            • Disadvantages of Star-Delta starter
            • Features of star-delta starting
            • Application of Star-Delta Starter
            • LESSON 1 WIRING SYSTEM OF SINGLE PHASE DISTRIBUTION BOARD
            • LESSON 2 WIRING SYSTEM OF SINGLE PHASE LIGHTING CIRCUIT
            • LESSON 3ndash WIRING SYSTEM OF SINGLE PHASE POWER CIRCUIT
            • LESSON 4ndash CONDUIT BENDING AND TRUNKING FABRICATION TECHNIQUE
            • LESSON 5 ndashWIRING SYSTEM OF 1 Oslash LIGHTING AND POWER CIRCUIT
              • POWER CIRCUITS
                • LESSON 6 ndash WIRING SYSTEM OF 3 Oslash DISTRIBUTION BOARD
                • LESSON 7 ndash WIRING SYSTEM OF THREE PHASE LIGHTING AND POWER CIRCUIT
                • LESSON 8 INSPECTION AND TESTING OF ELECTRICAL INSTALLATION
                  • CONTINUITY TEST
                    • Polarity Test
                      • Earth Electrode Resistance Test
                      • Earth Electrode Resistance Measurement Method (Figure 86)
                        • Residual Current Device Test
                        • LESSON 9 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (DC)
                        • LESSON 10 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (AC)
                        • LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE
                        • LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
                          • LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
                          • LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
                          • LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
                            • a Dead circuit test
                            • b Life circuit test
                            • LESSON 16
                              • TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
                              • SELF-ASSESSMENT QUESTIONS
Page 81: WorksheetTask AMIN

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

  • ELECTRICITY SUPPLY SPECIFICATIONS
    • Legal Requirements
    • Determining Consumer Load Requirements
    • 2 CONTROL AND PROTECTION SYSTEM FOR ELECTRICAL WIRING
    • CABLE SELECTION
      • 32 Factors Related to Cable Current Carrying Capacity
      • Functions and Colour Identification of Non Flexible Cables
        • Conductor Insulation and Types of Wiring
        • Functions and Colour Identification of Non Flexible Cables
        • 3 SELECTION OF WIRING ACCESSORIES
        • EARTHING OF ELECTRICAL INSTALLATIONS
          • 4 SAFETY REQUIREMENTS FOR ELECTRICAL WIRING WORKS IN RESIDENTIAL BUILDINGS
            • Why Electric Shocks Occur
            • INSTALLATION CIRCUITS AND SYSTEMS
            • Working Principal of Star-Delta Starter
            • Star-delta Starter Consists following units
            • Power Circuit of Star Delta Starter
            • Control Circuit of Star-Delta Starter (Open Transition)
            • What is Open or Closed Transition Starting
            • Effect of Transient in Starter (Open Transient starter)
            • Size of each part of Star-Delta starter
            • Motor Starting Characteristics of Star-Delta Starter
            • Advantages of Star-Delta starter
            • Disadvantages of Star-Delta starter
            • Features of star-delta starting
            • Application of Star-Delta Starter
            • LESSON 1 WIRING SYSTEM OF SINGLE PHASE DISTRIBUTION BOARD
            • LESSON 2 WIRING SYSTEM OF SINGLE PHASE LIGHTING CIRCUIT
            • LESSON 3ndash WIRING SYSTEM OF SINGLE PHASE POWER CIRCUIT
            • LESSON 4ndash CONDUIT BENDING AND TRUNKING FABRICATION TECHNIQUE
            • LESSON 5 ndashWIRING SYSTEM OF 1 Oslash LIGHTING AND POWER CIRCUIT
              • POWER CIRCUITS
                • LESSON 6 ndash WIRING SYSTEM OF 3 Oslash DISTRIBUTION BOARD
                • LESSON 7 ndash WIRING SYSTEM OF THREE PHASE LIGHTING AND POWER CIRCUIT
                • LESSON 8 INSPECTION AND TESTING OF ELECTRICAL INSTALLATION
                  • CONTINUITY TEST
                    • Polarity Test
                      • Earth Electrode Resistance Test
                      • Earth Electrode Resistance Measurement Method (Figure 86)
                        • Residual Current Device Test
                        • LESSON 9 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (DC)
                        • LESSON 10 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (AC)
                        • LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE
                        • LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
                          • LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
                          • LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
                          • LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
                            • a Dead circuit test
                            • b Life circuit test
                            • LESSON 16
                              • TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
                              • SELF-ASSESSMENT QUESTIONS
Page 82: WorksheetTask AMIN

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

  • ELECTRICITY SUPPLY SPECIFICATIONS
    • Legal Requirements
    • Determining Consumer Load Requirements
    • 2 CONTROL AND PROTECTION SYSTEM FOR ELECTRICAL WIRING
    • CABLE SELECTION
      • 32 Factors Related to Cable Current Carrying Capacity
      • Functions and Colour Identification of Non Flexible Cables
        • Conductor Insulation and Types of Wiring
        • Functions and Colour Identification of Non Flexible Cables
        • 3 SELECTION OF WIRING ACCESSORIES
        • EARTHING OF ELECTRICAL INSTALLATIONS
          • 4 SAFETY REQUIREMENTS FOR ELECTRICAL WIRING WORKS IN RESIDENTIAL BUILDINGS
            • Why Electric Shocks Occur
            • INSTALLATION CIRCUITS AND SYSTEMS
            • Working Principal of Star-Delta Starter
            • Star-delta Starter Consists following units
            • Power Circuit of Star Delta Starter
            • Control Circuit of Star-Delta Starter (Open Transition)
            • What is Open or Closed Transition Starting
            • Effect of Transient in Starter (Open Transient starter)
            • Size of each part of Star-Delta starter
            • Motor Starting Characteristics of Star-Delta Starter
            • Advantages of Star-Delta starter
            • Disadvantages of Star-Delta starter
            • Features of star-delta starting
            • Application of Star-Delta Starter
            • LESSON 1 WIRING SYSTEM OF SINGLE PHASE DISTRIBUTION BOARD
            • LESSON 2 WIRING SYSTEM OF SINGLE PHASE LIGHTING CIRCUIT
            • LESSON 3ndash WIRING SYSTEM OF SINGLE PHASE POWER CIRCUIT
            • LESSON 4ndash CONDUIT BENDING AND TRUNKING FABRICATION TECHNIQUE
            • LESSON 5 ndashWIRING SYSTEM OF 1 Oslash LIGHTING AND POWER CIRCUIT
              • POWER CIRCUITS
                • LESSON 6 ndash WIRING SYSTEM OF 3 Oslash DISTRIBUTION BOARD
                • LESSON 7 ndash WIRING SYSTEM OF THREE PHASE LIGHTING AND POWER CIRCUIT
                • LESSON 8 INSPECTION AND TESTING OF ELECTRICAL INSTALLATION
                  • CONTINUITY TEST
                    • Polarity Test
                      • Earth Electrode Resistance Test
                      • Earth Electrode Resistance Measurement Method (Figure 86)
                        • Residual Current Device Test
                        • LESSON 9 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (DC)
                        • LESSON 10 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (AC)
                        • LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE
                        • LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
                          • LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
                          • LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
                          • LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
                            • a Dead circuit test
                            • b Life circuit test
                            • LESSON 16
                              • TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
                              • SELF-ASSESSMENT QUESTIONS
Page 83: WorksheetTask AMIN

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

  • ELECTRICITY SUPPLY SPECIFICATIONS
    • Legal Requirements
    • Determining Consumer Load Requirements
    • 2 CONTROL AND PROTECTION SYSTEM FOR ELECTRICAL WIRING
    • CABLE SELECTION
      • 32 Factors Related to Cable Current Carrying Capacity
      • Functions and Colour Identification of Non Flexible Cables
        • Conductor Insulation and Types of Wiring
        • Functions and Colour Identification of Non Flexible Cables
        • 3 SELECTION OF WIRING ACCESSORIES
        • EARTHING OF ELECTRICAL INSTALLATIONS
          • 4 SAFETY REQUIREMENTS FOR ELECTRICAL WIRING WORKS IN RESIDENTIAL BUILDINGS
            • Why Electric Shocks Occur
            • INSTALLATION CIRCUITS AND SYSTEMS
            • Working Principal of Star-Delta Starter
            • Star-delta Starter Consists following units
            • Power Circuit of Star Delta Starter
            • Control Circuit of Star-Delta Starter (Open Transition)
            • What is Open or Closed Transition Starting
            • Effect of Transient in Starter (Open Transient starter)
            • Size of each part of Star-Delta starter
            • Motor Starting Characteristics of Star-Delta Starter
            • Advantages of Star-Delta starter
            • Disadvantages of Star-Delta starter
            • Features of star-delta starting
            • Application of Star-Delta Starter
            • LESSON 1 WIRING SYSTEM OF SINGLE PHASE DISTRIBUTION BOARD
            • LESSON 2 WIRING SYSTEM OF SINGLE PHASE LIGHTING CIRCUIT
            • LESSON 3ndash WIRING SYSTEM OF SINGLE PHASE POWER CIRCUIT
            • LESSON 4ndash CONDUIT BENDING AND TRUNKING FABRICATION TECHNIQUE
            • LESSON 5 ndashWIRING SYSTEM OF 1 Oslash LIGHTING AND POWER CIRCUIT
              • POWER CIRCUITS
                • LESSON 6 ndash WIRING SYSTEM OF 3 Oslash DISTRIBUTION BOARD
                • LESSON 7 ndash WIRING SYSTEM OF THREE PHASE LIGHTING AND POWER CIRCUIT
                • LESSON 8 INSPECTION AND TESTING OF ELECTRICAL INSTALLATION
                  • CONTINUITY TEST
                    • Polarity Test
                      • Earth Electrode Resistance Test
                      • Earth Electrode Resistance Measurement Method (Figure 86)
                        • Residual Current Device Test
                        • LESSON 9 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (DC)
                        • LESSON 10 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (AC)
                        • LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE
                        • LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
                          • LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
                          • LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
                          • LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
                            • a Dead circuit test
                            • b Life circuit test
                            • LESSON 16
                              • TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
                              • SELF-ASSESSMENT QUESTIONS
Page 84: WorksheetTask AMIN

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

  • ELECTRICITY SUPPLY SPECIFICATIONS
    • Legal Requirements
    • Determining Consumer Load Requirements
    • 2 CONTROL AND PROTECTION SYSTEM FOR ELECTRICAL WIRING
    • CABLE SELECTION
      • 32 Factors Related to Cable Current Carrying Capacity
      • Functions and Colour Identification of Non Flexible Cables
        • Conductor Insulation and Types of Wiring
        • Functions and Colour Identification of Non Flexible Cables
        • 3 SELECTION OF WIRING ACCESSORIES
        • EARTHING OF ELECTRICAL INSTALLATIONS
          • 4 SAFETY REQUIREMENTS FOR ELECTRICAL WIRING WORKS IN RESIDENTIAL BUILDINGS
            • Why Electric Shocks Occur
            • INSTALLATION CIRCUITS AND SYSTEMS
            • Working Principal of Star-Delta Starter
            • Star-delta Starter Consists following units
            • Power Circuit of Star Delta Starter
            • Control Circuit of Star-Delta Starter (Open Transition)
            • What is Open or Closed Transition Starting
            • Effect of Transient in Starter (Open Transient starter)
            • Size of each part of Star-Delta starter
            • Motor Starting Characteristics of Star-Delta Starter
            • Advantages of Star-Delta starter
            • Disadvantages of Star-Delta starter
            • Features of star-delta starting
            • Application of Star-Delta Starter
            • LESSON 1 WIRING SYSTEM OF SINGLE PHASE DISTRIBUTION BOARD
            • LESSON 2 WIRING SYSTEM OF SINGLE PHASE LIGHTING CIRCUIT
            • LESSON 3ndash WIRING SYSTEM OF SINGLE PHASE POWER CIRCUIT
            • LESSON 4ndash CONDUIT BENDING AND TRUNKING FABRICATION TECHNIQUE
            • LESSON 5 ndashWIRING SYSTEM OF 1 Oslash LIGHTING AND POWER CIRCUIT
              • POWER CIRCUITS
                • LESSON 6 ndash WIRING SYSTEM OF 3 Oslash DISTRIBUTION BOARD
                • LESSON 7 ndash WIRING SYSTEM OF THREE PHASE LIGHTING AND POWER CIRCUIT
                • LESSON 8 INSPECTION AND TESTING OF ELECTRICAL INSTALLATION
                  • CONTINUITY TEST
                    • Polarity Test
                      • Earth Electrode Resistance Test
                      • Earth Electrode Resistance Measurement Method (Figure 86)
                        • Residual Current Device Test
                        • LESSON 9 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (DC)
                        • LESSON 10 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (AC)
                        • LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE
                        • LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
                          • LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
                          • LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
                          • LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
                            • a Dead circuit test
                            • b Life circuit test
                            • LESSON 16
                              • TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
                              • SELF-ASSESSMENT QUESTIONS
Page 85: WorksheetTask AMIN

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

  • ELECTRICITY SUPPLY SPECIFICATIONS
    • Legal Requirements
    • Determining Consumer Load Requirements
    • 2 CONTROL AND PROTECTION SYSTEM FOR ELECTRICAL WIRING
    • CABLE SELECTION
      • 32 Factors Related to Cable Current Carrying Capacity
      • Functions and Colour Identification of Non Flexible Cables
        • Conductor Insulation and Types of Wiring
        • Functions and Colour Identification of Non Flexible Cables
        • 3 SELECTION OF WIRING ACCESSORIES
        • EARTHING OF ELECTRICAL INSTALLATIONS
          • 4 SAFETY REQUIREMENTS FOR ELECTRICAL WIRING WORKS IN RESIDENTIAL BUILDINGS
            • Why Electric Shocks Occur
            • INSTALLATION CIRCUITS AND SYSTEMS
            • Working Principal of Star-Delta Starter
            • Star-delta Starter Consists following units
            • Power Circuit of Star Delta Starter
            • Control Circuit of Star-Delta Starter (Open Transition)
            • What is Open or Closed Transition Starting
            • Effect of Transient in Starter (Open Transient starter)
            • Size of each part of Star-Delta starter
            • Motor Starting Characteristics of Star-Delta Starter
            • Advantages of Star-Delta starter
            • Disadvantages of Star-Delta starter
            • Features of star-delta starting
            • Application of Star-Delta Starter
            • LESSON 1 WIRING SYSTEM OF SINGLE PHASE DISTRIBUTION BOARD
            • LESSON 2 WIRING SYSTEM OF SINGLE PHASE LIGHTING CIRCUIT
            • LESSON 3ndash WIRING SYSTEM OF SINGLE PHASE POWER CIRCUIT
            • LESSON 4ndash CONDUIT BENDING AND TRUNKING FABRICATION TECHNIQUE
            • LESSON 5 ndashWIRING SYSTEM OF 1 Oslash LIGHTING AND POWER CIRCUIT
              • POWER CIRCUITS
                • LESSON 6 ndash WIRING SYSTEM OF 3 Oslash DISTRIBUTION BOARD
                • LESSON 7 ndash WIRING SYSTEM OF THREE PHASE LIGHTING AND POWER CIRCUIT
                • LESSON 8 INSPECTION AND TESTING OF ELECTRICAL INSTALLATION
                  • CONTINUITY TEST
                    • Polarity Test
                      • Earth Electrode Resistance Test
                      • Earth Electrode Resistance Measurement Method (Figure 86)
                        • Residual Current Device Test
                        • LESSON 9 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (DC)
                        • LESSON 10 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (AC)
                        • LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE
                        • LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
                          • LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
                          • LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
                          • LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
                            • a Dead circuit test
                            • b Life circuit test
                            • LESSON 16
                              • TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
                              • SELF-ASSESSMENT QUESTIONS
Page 86: WorksheetTask AMIN

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

  • ELECTRICITY SUPPLY SPECIFICATIONS
    • Legal Requirements
    • Determining Consumer Load Requirements
    • 2 CONTROL AND PROTECTION SYSTEM FOR ELECTRICAL WIRING
    • CABLE SELECTION
      • 32 Factors Related to Cable Current Carrying Capacity
      • Functions and Colour Identification of Non Flexible Cables
        • Conductor Insulation and Types of Wiring
        • Functions and Colour Identification of Non Flexible Cables
        • 3 SELECTION OF WIRING ACCESSORIES
        • EARTHING OF ELECTRICAL INSTALLATIONS
          • 4 SAFETY REQUIREMENTS FOR ELECTRICAL WIRING WORKS IN RESIDENTIAL BUILDINGS
            • Why Electric Shocks Occur
            • INSTALLATION CIRCUITS AND SYSTEMS
            • Working Principal of Star-Delta Starter
            • Star-delta Starter Consists following units
            • Power Circuit of Star Delta Starter
            • Control Circuit of Star-Delta Starter (Open Transition)
            • What is Open or Closed Transition Starting
            • Effect of Transient in Starter (Open Transient starter)
            • Size of each part of Star-Delta starter
            • Motor Starting Characteristics of Star-Delta Starter
            • Advantages of Star-Delta starter
            • Disadvantages of Star-Delta starter
            • Features of star-delta starting
            • Application of Star-Delta Starter
            • LESSON 1 WIRING SYSTEM OF SINGLE PHASE DISTRIBUTION BOARD
            • LESSON 2 WIRING SYSTEM OF SINGLE PHASE LIGHTING CIRCUIT
            • LESSON 3ndash WIRING SYSTEM OF SINGLE PHASE POWER CIRCUIT
            • LESSON 4ndash CONDUIT BENDING AND TRUNKING FABRICATION TECHNIQUE
            • LESSON 5 ndashWIRING SYSTEM OF 1 Oslash LIGHTING AND POWER CIRCUIT
              • POWER CIRCUITS
                • LESSON 6 ndash WIRING SYSTEM OF 3 Oslash DISTRIBUTION BOARD
                • LESSON 7 ndash WIRING SYSTEM OF THREE PHASE LIGHTING AND POWER CIRCUIT
                • LESSON 8 INSPECTION AND TESTING OF ELECTRICAL INSTALLATION
                  • CONTINUITY TEST
                    • Polarity Test
                      • Earth Electrode Resistance Test
                      • Earth Electrode Resistance Measurement Method (Figure 86)
                        • Residual Current Device Test
                        • LESSON 9 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (DC)
                        • LESSON 10 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (AC)
                        • LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE
                        • LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
                          • LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
                          • LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
                          • LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
                            • a Dead circuit test
                            • b Life circuit test
                            • LESSON 16
                              • TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
                              • SELF-ASSESSMENT QUESTIONS
Page 87: WorksheetTask AMIN

EZTECH ELECTRICAL INSTALLATION GUIDE

TOOLS MATERIAL SPECIFICATION QUANTITY

1 Mounting board 600 x 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

  • ELECTRICITY SUPPLY SPECIFICATIONS
    • Legal Requirements
    • Determining Consumer Load Requirements
    • 2 CONTROL AND PROTECTION SYSTEM FOR ELECTRICAL WIRING
    • CABLE SELECTION
      • 32 Factors Related to Cable Current Carrying Capacity
      • Functions and Colour Identification of Non Flexible Cables
        • Conductor Insulation and Types of Wiring
        • Functions and Colour Identification of Non Flexible Cables
        • 3 SELECTION OF WIRING ACCESSORIES
        • EARTHING OF ELECTRICAL INSTALLATIONS
          • 4 SAFETY REQUIREMENTS FOR ELECTRICAL WIRING WORKS IN RESIDENTIAL BUILDINGS
            • Why Electric Shocks Occur
            • INSTALLATION CIRCUITS AND SYSTEMS
            • Working Principal of Star-Delta Starter
            • Star-delta Starter Consists following units
            • Power Circuit of Star Delta Starter
            • Control Circuit of Star-Delta Starter (Open Transition)
            • What is Open or Closed Transition Starting
            • Effect of Transient in Starter (Open Transient starter)
            • Size of each part of Star-Delta starter
            • Motor Starting Characteristics of Star-Delta Starter
            • Advantages of Star-Delta starter
            • Disadvantages of Star-Delta starter
            • Features of star-delta starting
            • Application of Star-Delta Starter
            • LESSON 1 WIRING SYSTEM OF SINGLE PHASE DISTRIBUTION BOARD
            • LESSON 2 WIRING SYSTEM OF SINGLE PHASE LIGHTING CIRCUIT
            • LESSON 3ndash WIRING SYSTEM OF SINGLE PHASE POWER CIRCUIT
            • LESSON 4ndash CONDUIT BENDING AND TRUNKING FABRICATION TECHNIQUE
            • LESSON 5 ndashWIRING SYSTEM OF 1 Oslash LIGHTING AND POWER CIRCUIT
              • POWER CIRCUITS
                • LESSON 6 ndash WIRING SYSTEM OF 3 Oslash DISTRIBUTION BOARD
                • LESSON 7 ndash WIRING SYSTEM OF THREE PHASE LIGHTING AND POWER CIRCUIT
                • LESSON 8 INSPECTION AND TESTING OF ELECTRICAL INSTALLATION
                  • CONTINUITY TEST
                    • Polarity Test
                      • Earth Electrode Resistance Test
                      • Earth Electrode Resistance Measurement Method (Figure 86)
                        • Residual Current Device Test
                        • LESSON 9 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (DC)
                        • LESSON 10 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (AC)
                        • LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE
                        • LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
                          • LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
                          • LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
                          • LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
                            • a Dead circuit test
                            • b Life circuit test
                            • LESSON 16
                              • TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
                              • SELF-ASSESSMENT QUESTIONS
Page 88: WorksheetTask AMIN

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

  • ELECTRICITY SUPPLY SPECIFICATIONS
    • Legal Requirements
    • Determining Consumer Load Requirements
    • 2 CONTROL AND PROTECTION SYSTEM FOR ELECTRICAL WIRING
    • CABLE SELECTION
      • 32 Factors Related to Cable Current Carrying Capacity
      • Functions and Colour Identification of Non Flexible Cables
        • Conductor Insulation and Types of Wiring
        • Functions and Colour Identification of Non Flexible Cables
        • 3 SELECTION OF WIRING ACCESSORIES
        • EARTHING OF ELECTRICAL INSTALLATIONS
          • 4 SAFETY REQUIREMENTS FOR ELECTRICAL WIRING WORKS IN RESIDENTIAL BUILDINGS
            • Why Electric Shocks Occur
            • INSTALLATION CIRCUITS AND SYSTEMS
            • Working Principal of Star-Delta Starter
            • Star-delta Starter Consists following units
            • Power Circuit of Star Delta Starter
            • Control Circuit of Star-Delta Starter (Open Transition)
            • What is Open or Closed Transition Starting
            • Effect of Transient in Starter (Open Transient starter)
            • Size of each part of Star-Delta starter
            • Motor Starting Characteristics of Star-Delta Starter
            • Advantages of Star-Delta starter
            • Disadvantages of Star-Delta starter
            • Features of star-delta starting
            • Application of Star-Delta Starter
            • LESSON 1 WIRING SYSTEM OF SINGLE PHASE DISTRIBUTION BOARD
            • LESSON 2 WIRING SYSTEM OF SINGLE PHASE LIGHTING CIRCUIT
            • LESSON 3ndash WIRING SYSTEM OF SINGLE PHASE POWER CIRCUIT
            • LESSON 4ndash CONDUIT BENDING AND TRUNKING FABRICATION TECHNIQUE
            • LESSON 5 ndashWIRING SYSTEM OF 1 Oslash LIGHTING AND POWER CIRCUIT
              • POWER CIRCUITS
                • LESSON 6 ndash WIRING SYSTEM OF 3 Oslash DISTRIBUTION BOARD
                • LESSON 7 ndash WIRING SYSTEM OF THREE PHASE LIGHTING AND POWER CIRCUIT
                • LESSON 8 INSPECTION AND TESTING OF ELECTRICAL INSTALLATION
                  • CONTINUITY TEST
                    • Polarity Test
                      • Earth Electrode Resistance Test
                      • Earth Electrode Resistance Measurement Method (Figure 86)
                        • Residual Current Device Test
                        • LESSON 9 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (DC)
                        • LESSON 10 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (AC)
                        • LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE
                        • LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
                          • LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
                          • LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
                          • LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
                            • a Dead circuit test
                            • b Life circuit test
                            • LESSON 16
                              • TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
                              • SELF-ASSESSMENT QUESTIONS
Page 89: WorksheetTask AMIN

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

  • ELECTRICITY SUPPLY SPECIFICATIONS
    • Legal Requirements
    • Determining Consumer Load Requirements
    • 2 CONTROL AND PROTECTION SYSTEM FOR ELECTRICAL WIRING
    • CABLE SELECTION
      • 32 Factors Related to Cable Current Carrying Capacity
      • Functions and Colour Identification of Non Flexible Cables
        • Conductor Insulation and Types of Wiring
        • Functions and Colour Identification of Non Flexible Cables
        • 3 SELECTION OF WIRING ACCESSORIES
        • EARTHING OF ELECTRICAL INSTALLATIONS
          • 4 SAFETY REQUIREMENTS FOR ELECTRICAL WIRING WORKS IN RESIDENTIAL BUILDINGS
            • Why Electric Shocks Occur
            • INSTALLATION CIRCUITS AND SYSTEMS
            • Working Principal of Star-Delta Starter
            • Star-delta Starter Consists following units
            • Power Circuit of Star Delta Starter
            • Control Circuit of Star-Delta Starter (Open Transition)
            • What is Open or Closed Transition Starting
            • Effect of Transient in Starter (Open Transient starter)
            • Size of each part of Star-Delta starter
            • Motor Starting Characteristics of Star-Delta Starter
            • Advantages of Star-Delta starter
            • Disadvantages of Star-Delta starter
            • Features of star-delta starting
            • Application of Star-Delta Starter
            • LESSON 1 WIRING SYSTEM OF SINGLE PHASE DISTRIBUTION BOARD
            • LESSON 2 WIRING SYSTEM OF SINGLE PHASE LIGHTING CIRCUIT
            • LESSON 3ndash WIRING SYSTEM OF SINGLE PHASE POWER CIRCUIT
            • LESSON 4ndash CONDUIT BENDING AND TRUNKING FABRICATION TECHNIQUE
            • LESSON 5 ndashWIRING SYSTEM OF 1 Oslash LIGHTING AND POWER CIRCUIT
              • POWER CIRCUITS
                • LESSON 6 ndash WIRING SYSTEM OF 3 Oslash DISTRIBUTION BOARD
                • LESSON 7 ndash WIRING SYSTEM OF THREE PHASE LIGHTING AND POWER CIRCUIT
                • LESSON 8 INSPECTION AND TESTING OF ELECTRICAL INSTALLATION
                  • CONTINUITY TEST
                    • Polarity Test
                      • Earth Electrode Resistance Test
                      • Earth Electrode Resistance Measurement Method (Figure 86)
                        • Residual Current Device Test
                        • LESSON 9 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (DC)
                        • LESSON 10 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (AC)
                        • LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE
                        • LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
                          • LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
                          • LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
                          • LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
                            • a Dead circuit test
                            • b Life circuit test
                            • LESSON 16
                              • TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
                              • SELF-ASSESSMENT QUESTIONS
Page 90: WorksheetTask AMIN

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

  • ELECTRICITY SUPPLY SPECIFICATIONS
    • Legal Requirements
    • Determining Consumer Load Requirements
    • 2 CONTROL AND PROTECTION SYSTEM FOR ELECTRICAL WIRING
    • CABLE SELECTION
      • 32 Factors Related to Cable Current Carrying Capacity
      • Functions and Colour Identification of Non Flexible Cables
        • Conductor Insulation and Types of Wiring
        • Functions and Colour Identification of Non Flexible Cables
        • 3 SELECTION OF WIRING ACCESSORIES
        • EARTHING OF ELECTRICAL INSTALLATIONS
          • 4 SAFETY REQUIREMENTS FOR ELECTRICAL WIRING WORKS IN RESIDENTIAL BUILDINGS
            • Why Electric Shocks Occur
            • INSTALLATION CIRCUITS AND SYSTEMS
            • Working Principal of Star-Delta Starter
            • Star-delta Starter Consists following units
            • Power Circuit of Star Delta Starter
            • Control Circuit of Star-Delta Starter (Open Transition)
            • What is Open or Closed Transition Starting
            • Effect of Transient in Starter (Open Transient starter)
            • Size of each part of Star-Delta starter
            • Motor Starting Characteristics of Star-Delta Starter
            • Advantages of Star-Delta starter
            • Disadvantages of Star-Delta starter
            • Features of star-delta starting
            • Application of Star-Delta Starter
            • LESSON 1 WIRING SYSTEM OF SINGLE PHASE DISTRIBUTION BOARD
            • LESSON 2 WIRING SYSTEM OF SINGLE PHASE LIGHTING CIRCUIT
            • LESSON 3ndash WIRING SYSTEM OF SINGLE PHASE POWER CIRCUIT
            • LESSON 4ndash CONDUIT BENDING AND TRUNKING FABRICATION TECHNIQUE
            • LESSON 5 ndashWIRING SYSTEM OF 1 Oslash LIGHTING AND POWER CIRCUIT
              • POWER CIRCUITS
                • LESSON 6 ndash WIRING SYSTEM OF 3 Oslash DISTRIBUTION BOARD
                • LESSON 7 ndash WIRING SYSTEM OF THREE PHASE LIGHTING AND POWER CIRCUIT
                • LESSON 8 INSPECTION AND TESTING OF ELECTRICAL INSTALLATION
                  • CONTINUITY TEST
                    • Polarity Test
                      • Earth Electrode Resistance Test
                      • Earth Electrode Resistance Measurement Method (Figure 86)
                        • Residual Current Device Test
                        • LESSON 9 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (DC)
                        • LESSON 10 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (AC)
                        • LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE
                        • LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
                          • LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
                          • LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
                          • LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
                            • a Dead circuit test
                            • b Life circuit test
                            • LESSON 16
                              • TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
                              • SELF-ASSESSMENT QUESTIONS
Page 91: WorksheetTask AMIN

EZTECH ELECTRICAL INSTALLATION GUIDE

TOOLS MATERIAL SPECIFICATION QUANTITY

1 Mounting board 600 x 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

  • ELECTRICITY SUPPLY SPECIFICATIONS
    • Legal Requirements
    • Determining Consumer Load Requirements
    • 2 CONTROL AND PROTECTION SYSTEM FOR ELECTRICAL WIRING
    • CABLE SELECTION
      • 32 Factors Related to Cable Current Carrying Capacity
      • Functions and Colour Identification of Non Flexible Cables
        • Conductor Insulation and Types of Wiring
        • Functions and Colour Identification of Non Flexible Cables
        • 3 SELECTION OF WIRING ACCESSORIES
        • EARTHING OF ELECTRICAL INSTALLATIONS
          • 4 SAFETY REQUIREMENTS FOR ELECTRICAL WIRING WORKS IN RESIDENTIAL BUILDINGS
            • Why Electric Shocks Occur
            • INSTALLATION CIRCUITS AND SYSTEMS
            • Working Principal of Star-Delta Starter
            • Star-delta Starter Consists following units
            • Power Circuit of Star Delta Starter
            • Control Circuit of Star-Delta Starter (Open Transition)
            • What is Open or Closed Transition Starting
            • Effect of Transient in Starter (Open Transient starter)
            • Size of each part of Star-Delta starter
            • Motor Starting Characteristics of Star-Delta Starter
            • Advantages of Star-Delta starter
            • Disadvantages of Star-Delta starter
            • Features of star-delta starting
            • Application of Star-Delta Starter
            • LESSON 1 WIRING SYSTEM OF SINGLE PHASE DISTRIBUTION BOARD
            • LESSON 2 WIRING SYSTEM OF SINGLE PHASE LIGHTING CIRCUIT
            • LESSON 3ndash WIRING SYSTEM OF SINGLE PHASE POWER CIRCUIT
            • LESSON 4ndash CONDUIT BENDING AND TRUNKING FABRICATION TECHNIQUE
            • LESSON 5 ndashWIRING SYSTEM OF 1 Oslash LIGHTING AND POWER CIRCUIT
              • POWER CIRCUITS
                • LESSON 6 ndash WIRING SYSTEM OF 3 Oslash DISTRIBUTION BOARD
                • LESSON 7 ndash WIRING SYSTEM OF THREE PHASE LIGHTING AND POWER CIRCUIT
                • LESSON 8 INSPECTION AND TESTING OF ELECTRICAL INSTALLATION
                  • CONTINUITY TEST
                    • Polarity Test
                      • Earth Electrode Resistance Test
                      • Earth Electrode Resistance Measurement Method (Figure 86)
                        • Residual Current Device Test
                        • LESSON 9 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (DC)
                        • LESSON 10 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (AC)
                        • LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE
                        • LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
                          • LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
                          • LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
                          • LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
                            • a Dead circuit test
                            • b Life circuit test
                            • LESSON 16
                              • TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
                              • SELF-ASSESSMENT QUESTIONS
Page 92: WorksheetTask AMIN

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

  • ELECTRICITY SUPPLY SPECIFICATIONS
    • Legal Requirements
    • Determining Consumer Load Requirements
    • 2 CONTROL AND PROTECTION SYSTEM FOR ELECTRICAL WIRING
    • CABLE SELECTION
      • 32 Factors Related to Cable Current Carrying Capacity
      • Functions and Colour Identification of Non Flexible Cables
        • Conductor Insulation and Types of Wiring
        • Functions and Colour Identification of Non Flexible Cables
        • 3 SELECTION OF WIRING ACCESSORIES
        • EARTHING OF ELECTRICAL INSTALLATIONS
          • 4 SAFETY REQUIREMENTS FOR ELECTRICAL WIRING WORKS IN RESIDENTIAL BUILDINGS
            • Why Electric Shocks Occur
            • INSTALLATION CIRCUITS AND SYSTEMS
            • Working Principal of Star-Delta Starter
            • Star-delta Starter Consists following units
            • Power Circuit of Star Delta Starter
            • Control Circuit of Star-Delta Starter (Open Transition)
            • What is Open or Closed Transition Starting
            • Effect of Transient in Starter (Open Transient starter)
            • Size of each part of Star-Delta starter
            • Motor Starting Characteristics of Star-Delta Starter
            • Advantages of Star-Delta starter
            • Disadvantages of Star-Delta starter
            • Features of star-delta starting
            • Application of Star-Delta Starter
            • LESSON 1 WIRING SYSTEM OF SINGLE PHASE DISTRIBUTION BOARD
            • LESSON 2 WIRING SYSTEM OF SINGLE PHASE LIGHTING CIRCUIT
            • LESSON 3ndash WIRING SYSTEM OF SINGLE PHASE POWER CIRCUIT
            • LESSON 4ndash CONDUIT BENDING AND TRUNKING FABRICATION TECHNIQUE
            • LESSON 5 ndashWIRING SYSTEM OF 1 Oslash LIGHTING AND POWER CIRCUIT
              • POWER CIRCUITS
                • LESSON 6 ndash WIRING SYSTEM OF 3 Oslash DISTRIBUTION BOARD
                • LESSON 7 ndash WIRING SYSTEM OF THREE PHASE LIGHTING AND POWER CIRCUIT
                • LESSON 8 INSPECTION AND TESTING OF ELECTRICAL INSTALLATION
                  • CONTINUITY TEST
                    • Polarity Test
                      • Earth Electrode Resistance Test
                      • Earth Electrode Resistance Measurement Method (Figure 86)
                        • Residual Current Device Test
                        • LESSON 9 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (DC)
                        • LESSON 10 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (AC)
                        • LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE
                        • LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
                          • LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
                          • LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
                          • LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
                            • a Dead circuit test
                            • b Life circuit test
                            • LESSON 16
                              • TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
                              • SELF-ASSESSMENT QUESTIONS
Page 93: WorksheetTask AMIN

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

  • ELECTRICITY SUPPLY SPECIFICATIONS
    • Legal Requirements
    • Determining Consumer Load Requirements
    • 2 CONTROL AND PROTECTION SYSTEM FOR ELECTRICAL WIRING
    • CABLE SELECTION
      • 32 Factors Related to Cable Current Carrying Capacity
      • Functions and Colour Identification of Non Flexible Cables
        • Conductor Insulation and Types of Wiring
        • Functions and Colour Identification of Non Flexible Cables
        • 3 SELECTION OF WIRING ACCESSORIES
        • EARTHING OF ELECTRICAL INSTALLATIONS
          • 4 SAFETY REQUIREMENTS FOR ELECTRICAL WIRING WORKS IN RESIDENTIAL BUILDINGS
            • Why Electric Shocks Occur
            • INSTALLATION CIRCUITS AND SYSTEMS
            • Working Principal of Star-Delta Starter
            • Star-delta Starter Consists following units
            • Power Circuit of Star Delta Starter
            • Control Circuit of Star-Delta Starter (Open Transition)
            • What is Open or Closed Transition Starting
            • Effect of Transient in Starter (Open Transient starter)
            • Size of each part of Star-Delta starter
            • Motor Starting Characteristics of Star-Delta Starter
            • Advantages of Star-Delta starter
            • Disadvantages of Star-Delta starter
            • Features of star-delta starting
            • Application of Star-Delta Starter
            • LESSON 1 WIRING SYSTEM OF SINGLE PHASE DISTRIBUTION BOARD
            • LESSON 2 WIRING SYSTEM OF SINGLE PHASE LIGHTING CIRCUIT
            • LESSON 3ndash WIRING SYSTEM OF SINGLE PHASE POWER CIRCUIT
            • LESSON 4ndash CONDUIT BENDING AND TRUNKING FABRICATION TECHNIQUE
            • LESSON 5 ndashWIRING SYSTEM OF 1 Oslash LIGHTING AND POWER CIRCUIT
              • POWER CIRCUITS
                • LESSON 6 ndash WIRING SYSTEM OF 3 Oslash DISTRIBUTION BOARD
                • LESSON 7 ndash WIRING SYSTEM OF THREE PHASE LIGHTING AND POWER CIRCUIT
                • LESSON 8 INSPECTION AND TESTING OF ELECTRICAL INSTALLATION
                  • CONTINUITY TEST
                    • Polarity Test
                      • Earth Electrode Resistance Test
                      • Earth Electrode Resistance Measurement Method (Figure 86)
                        • Residual Current Device Test
                        • LESSON 9 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (DC)
                        • LESSON 10 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (AC)
                        • LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE
                        • LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
                          • LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
                          • LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
                          • LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
                            • a Dead circuit test
                            • b Life circuit test
                            • LESSON 16
                              • TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
                              • SELF-ASSESSMENT QUESTIONS
Page 94: WorksheetTask AMIN

EZTECH ELECTRICAL INSTALLATION GUIDE

TOOLS MATERIAL SPECIFICATION QUANTITY

1 Mounting board 600 x 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

  • ELECTRICITY SUPPLY SPECIFICATIONS
    • Legal Requirements
    • Determining Consumer Load Requirements
    • 2 CONTROL AND PROTECTION SYSTEM FOR ELECTRICAL WIRING
    • CABLE SELECTION
      • 32 Factors Related to Cable Current Carrying Capacity
      • Functions and Colour Identification of Non Flexible Cables
        • Conductor Insulation and Types of Wiring
        • Functions and Colour Identification of Non Flexible Cables
        • 3 SELECTION OF WIRING ACCESSORIES
        • EARTHING OF ELECTRICAL INSTALLATIONS
          • 4 SAFETY REQUIREMENTS FOR ELECTRICAL WIRING WORKS IN RESIDENTIAL BUILDINGS
            • Why Electric Shocks Occur
            • INSTALLATION CIRCUITS AND SYSTEMS
            • Working Principal of Star-Delta Starter
            • Star-delta Starter Consists following units
            • Power Circuit of Star Delta Starter
            • Control Circuit of Star-Delta Starter (Open Transition)
            • What is Open or Closed Transition Starting
            • Effect of Transient in Starter (Open Transient starter)
            • Size of each part of Star-Delta starter
            • Motor Starting Characteristics of Star-Delta Starter
            • Advantages of Star-Delta starter
            • Disadvantages of Star-Delta starter
            • Features of star-delta starting
            • Application of Star-Delta Starter
            • LESSON 1 WIRING SYSTEM OF SINGLE PHASE DISTRIBUTION BOARD
            • LESSON 2 WIRING SYSTEM OF SINGLE PHASE LIGHTING CIRCUIT
            • LESSON 3ndash WIRING SYSTEM OF SINGLE PHASE POWER CIRCUIT
            • LESSON 4ndash CONDUIT BENDING AND TRUNKING FABRICATION TECHNIQUE
            • LESSON 5 ndashWIRING SYSTEM OF 1 Oslash LIGHTING AND POWER CIRCUIT
              • POWER CIRCUITS
                • LESSON 6 ndash WIRING SYSTEM OF 3 Oslash DISTRIBUTION BOARD
                • LESSON 7 ndash WIRING SYSTEM OF THREE PHASE LIGHTING AND POWER CIRCUIT
                • LESSON 8 INSPECTION AND TESTING OF ELECTRICAL INSTALLATION
                  • CONTINUITY TEST
                    • Polarity Test
                      • Earth Electrode Resistance Test
                      • Earth Electrode Resistance Measurement Method (Figure 86)
                        • Residual Current Device Test
                        • LESSON 9 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (DC)
                        • LESSON 10 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (AC)
                        • LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE
                        • LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
                          • LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
                          • LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
                          • LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
                            • a Dead circuit test
                            • b Life circuit test
                            • LESSON 16
                              • TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
                              • SELF-ASSESSMENT QUESTIONS
Page 95: WorksheetTask AMIN

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

  • ELECTRICITY SUPPLY SPECIFICATIONS
    • Legal Requirements
    • Determining Consumer Load Requirements
    • 2 CONTROL AND PROTECTION SYSTEM FOR ELECTRICAL WIRING
    • CABLE SELECTION
      • 32 Factors Related to Cable Current Carrying Capacity
      • Functions and Colour Identification of Non Flexible Cables
        • Conductor Insulation and Types of Wiring
        • Functions and Colour Identification of Non Flexible Cables
        • 3 SELECTION OF WIRING ACCESSORIES
        • EARTHING OF ELECTRICAL INSTALLATIONS
          • 4 SAFETY REQUIREMENTS FOR ELECTRICAL WIRING WORKS IN RESIDENTIAL BUILDINGS
            • Why Electric Shocks Occur
            • INSTALLATION CIRCUITS AND SYSTEMS
            • Working Principal of Star-Delta Starter
            • Star-delta Starter Consists following units
            • Power Circuit of Star Delta Starter
            • Control Circuit of Star-Delta Starter (Open Transition)
            • What is Open or Closed Transition Starting
            • Effect of Transient in Starter (Open Transient starter)
            • Size of each part of Star-Delta starter
            • Motor Starting Characteristics of Star-Delta Starter
            • Advantages of Star-Delta starter
            • Disadvantages of Star-Delta starter
            • Features of star-delta starting
            • Application of Star-Delta Starter
            • LESSON 1 WIRING SYSTEM OF SINGLE PHASE DISTRIBUTION BOARD
            • LESSON 2 WIRING SYSTEM OF SINGLE PHASE LIGHTING CIRCUIT
            • LESSON 3ndash WIRING SYSTEM OF SINGLE PHASE POWER CIRCUIT
            • LESSON 4ndash CONDUIT BENDING AND TRUNKING FABRICATION TECHNIQUE
            • LESSON 5 ndashWIRING SYSTEM OF 1 Oslash LIGHTING AND POWER CIRCUIT
              • POWER CIRCUITS
                • LESSON 6 ndash WIRING SYSTEM OF 3 Oslash DISTRIBUTION BOARD
                • LESSON 7 ndash WIRING SYSTEM OF THREE PHASE LIGHTING AND POWER CIRCUIT
                • LESSON 8 INSPECTION AND TESTING OF ELECTRICAL INSTALLATION
                  • CONTINUITY TEST
                    • Polarity Test
                      • Earth Electrode Resistance Test
                      • Earth Electrode Resistance Measurement Method (Figure 86)
                        • Residual Current Device Test
                        • LESSON 9 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (DC)
                        • LESSON 10 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (AC)
                        • LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE
                        • LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
                          • LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
                          • LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
                          • LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
                            • a Dead circuit test
                            • b Life circuit test
                            • LESSON 16
                              • TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
                              • SELF-ASSESSMENT QUESTIONS
Page 96: WorksheetTask AMIN

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

  • ELECTRICITY SUPPLY SPECIFICATIONS
    • Legal Requirements
    • Determining Consumer Load Requirements
    • 2 CONTROL AND PROTECTION SYSTEM FOR ELECTRICAL WIRING
    • CABLE SELECTION
      • 32 Factors Related to Cable Current Carrying Capacity
      • Functions and Colour Identification of Non Flexible Cables
        • Conductor Insulation and Types of Wiring
        • Functions and Colour Identification of Non Flexible Cables
        • 3 SELECTION OF WIRING ACCESSORIES
        • EARTHING OF ELECTRICAL INSTALLATIONS
          • 4 SAFETY REQUIREMENTS FOR ELECTRICAL WIRING WORKS IN RESIDENTIAL BUILDINGS
            • Why Electric Shocks Occur
            • INSTALLATION CIRCUITS AND SYSTEMS
            • Working Principal of Star-Delta Starter
            • Star-delta Starter Consists following units
            • Power Circuit of Star Delta Starter
            • Control Circuit of Star-Delta Starter (Open Transition)
            • What is Open or Closed Transition Starting
            • Effect of Transient in Starter (Open Transient starter)
            • Size of each part of Star-Delta starter
            • Motor Starting Characteristics of Star-Delta Starter
            • Advantages of Star-Delta starter
            • Disadvantages of Star-Delta starter
            • Features of star-delta starting
            • Application of Star-Delta Starter
            • LESSON 1 WIRING SYSTEM OF SINGLE PHASE DISTRIBUTION BOARD
            • LESSON 2 WIRING SYSTEM OF SINGLE PHASE LIGHTING CIRCUIT
            • LESSON 3ndash WIRING SYSTEM OF SINGLE PHASE POWER CIRCUIT
            • LESSON 4ndash CONDUIT BENDING AND TRUNKING FABRICATION TECHNIQUE
            • LESSON 5 ndashWIRING SYSTEM OF 1 Oslash LIGHTING AND POWER CIRCUIT
              • POWER CIRCUITS
                • LESSON 6 ndash WIRING SYSTEM OF 3 Oslash DISTRIBUTION BOARD
                • LESSON 7 ndash WIRING SYSTEM OF THREE PHASE LIGHTING AND POWER CIRCUIT
                • LESSON 8 INSPECTION AND TESTING OF ELECTRICAL INSTALLATION
                  • CONTINUITY TEST
                    • Polarity Test
                      • Earth Electrode Resistance Test
                      • Earth Electrode Resistance Measurement Method (Figure 86)
                        • Residual Current Device Test
                        • LESSON 9 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (DC)
                        • LESSON 10 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (AC)
                        • LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE
                        • LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
                          • LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
                          • LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
                          • LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
                            • a Dead circuit test
                            • b Life circuit test
                            • LESSON 16
                              • TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
                              • SELF-ASSESSMENT QUESTIONS
Page 97: WorksheetTask AMIN

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

  • ELECTRICITY SUPPLY SPECIFICATIONS
    • Legal Requirements
    • Determining Consumer Load Requirements
    • 2 CONTROL AND PROTECTION SYSTEM FOR ELECTRICAL WIRING
    • CABLE SELECTION
      • 32 Factors Related to Cable Current Carrying Capacity
      • Functions and Colour Identification of Non Flexible Cables
        • Conductor Insulation and Types of Wiring
        • Functions and Colour Identification of Non Flexible Cables
        • 3 SELECTION OF WIRING ACCESSORIES
        • EARTHING OF ELECTRICAL INSTALLATIONS
          • 4 SAFETY REQUIREMENTS FOR ELECTRICAL WIRING WORKS IN RESIDENTIAL BUILDINGS
            • Why Electric Shocks Occur
            • INSTALLATION CIRCUITS AND SYSTEMS
            • Working Principal of Star-Delta Starter
            • Star-delta Starter Consists following units
            • Power Circuit of Star Delta Starter
            • Control Circuit of Star-Delta Starter (Open Transition)
            • What is Open or Closed Transition Starting
            • Effect of Transient in Starter (Open Transient starter)
            • Size of each part of Star-Delta starter
            • Motor Starting Characteristics of Star-Delta Starter
            • Advantages of Star-Delta starter
            • Disadvantages of Star-Delta starter
            • Features of star-delta starting
            • Application of Star-Delta Starter
            • LESSON 1 WIRING SYSTEM OF SINGLE PHASE DISTRIBUTION BOARD
            • LESSON 2 WIRING SYSTEM OF SINGLE PHASE LIGHTING CIRCUIT
            • LESSON 3ndash WIRING SYSTEM OF SINGLE PHASE POWER CIRCUIT
            • LESSON 4ndash CONDUIT BENDING AND TRUNKING FABRICATION TECHNIQUE
            • LESSON 5 ndashWIRING SYSTEM OF 1 Oslash LIGHTING AND POWER CIRCUIT
              • POWER CIRCUITS
                • LESSON 6 ndash WIRING SYSTEM OF 3 Oslash DISTRIBUTION BOARD
                • LESSON 7 ndash WIRING SYSTEM OF THREE PHASE LIGHTING AND POWER CIRCUIT
                • LESSON 8 INSPECTION AND TESTING OF ELECTRICAL INSTALLATION
                  • CONTINUITY TEST
                    • Polarity Test
                      • Earth Electrode Resistance Test
                      • Earth Electrode Resistance Measurement Method (Figure 86)
                        • Residual Current Device Test
                        • LESSON 9 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (DC)
                        • LESSON 10 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (AC)
                        • LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE
                        • LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
                          • LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
                          • LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
                          • LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
                            • a Dead circuit test
                            • b Life circuit test
                            • LESSON 16
                              • TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
                              • SELF-ASSESSMENT QUESTIONS
Page 98: WorksheetTask AMIN

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

  • ELECTRICITY SUPPLY SPECIFICATIONS
    • Legal Requirements
    • Determining Consumer Load Requirements
    • 2 CONTROL AND PROTECTION SYSTEM FOR ELECTRICAL WIRING
    • CABLE SELECTION
      • 32 Factors Related to Cable Current Carrying Capacity
      • Functions and Colour Identification of Non Flexible Cables
        • Conductor Insulation and Types of Wiring
        • Functions and Colour Identification of Non Flexible Cables
        • 3 SELECTION OF WIRING ACCESSORIES
        • EARTHING OF ELECTRICAL INSTALLATIONS
          • 4 SAFETY REQUIREMENTS FOR ELECTRICAL WIRING WORKS IN RESIDENTIAL BUILDINGS
            • Why Electric Shocks Occur
            • INSTALLATION CIRCUITS AND SYSTEMS
            • Working Principal of Star-Delta Starter
            • Star-delta Starter Consists following units
            • Power Circuit of Star Delta Starter
            • Control Circuit of Star-Delta Starter (Open Transition)
            • What is Open or Closed Transition Starting
            • Effect of Transient in Starter (Open Transient starter)
            • Size of each part of Star-Delta starter
            • Motor Starting Characteristics of Star-Delta Starter
            • Advantages of Star-Delta starter
            • Disadvantages of Star-Delta starter
            • Features of star-delta starting
            • Application of Star-Delta Starter
            • LESSON 1 WIRING SYSTEM OF SINGLE PHASE DISTRIBUTION BOARD
            • LESSON 2 WIRING SYSTEM OF SINGLE PHASE LIGHTING CIRCUIT
            • LESSON 3ndash WIRING SYSTEM OF SINGLE PHASE POWER CIRCUIT
            • LESSON 4ndash CONDUIT BENDING AND TRUNKING FABRICATION TECHNIQUE
            • LESSON 5 ndashWIRING SYSTEM OF 1 Oslash LIGHTING AND POWER CIRCUIT
              • POWER CIRCUITS
                • LESSON 6 ndash WIRING SYSTEM OF 3 Oslash DISTRIBUTION BOARD
                • LESSON 7 ndash WIRING SYSTEM OF THREE PHASE LIGHTING AND POWER CIRCUIT
                • LESSON 8 INSPECTION AND TESTING OF ELECTRICAL INSTALLATION
                  • CONTINUITY TEST
                    • Polarity Test
                      • Earth Electrode Resistance Test
                      • Earth Electrode Resistance Measurement Method (Figure 86)
                        • Residual Current Device Test
                        • LESSON 9 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (DC)
                        • LESSON 10 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (AC)
                        • LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE
                        • LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
                          • LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
                          • LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
                          • LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
                            • a Dead circuit test
                            • b Life circuit test
                            • LESSON 16
                              • TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
                              • SELF-ASSESSMENT QUESTIONS
Page 99: WorksheetTask AMIN

EZTECH ELECTRICAL INSTALLATION GUIDE

APPENDIX 111

Attachment Reference

httpswwwtlc-directcoukBook621htm

httpwwwstgovmyindexphpms

15 ndash 99EASYTECH ENTERPRISE

  • ELECTRICITY SUPPLY SPECIFICATIONS
    • Legal Requirements
    • Determining Consumer Load Requirements
    • 2 CONTROL AND PROTECTION SYSTEM FOR ELECTRICAL WIRING
    • CABLE SELECTION
      • 32 Factors Related to Cable Current Carrying Capacity
      • Functions and Colour Identification of Non Flexible Cables
        • Conductor Insulation and Types of Wiring
        • Functions and Colour Identification of Non Flexible Cables
        • 3 SELECTION OF WIRING ACCESSORIES
        • EARTHING OF ELECTRICAL INSTALLATIONS
          • 4 SAFETY REQUIREMENTS FOR ELECTRICAL WIRING WORKS IN RESIDENTIAL BUILDINGS
            • Why Electric Shocks Occur
            • INSTALLATION CIRCUITS AND SYSTEMS
            • Working Principal of Star-Delta Starter
            • Star-delta Starter Consists following units
            • Power Circuit of Star Delta Starter
            • Control Circuit of Star-Delta Starter (Open Transition)
            • What is Open or Closed Transition Starting
            • Effect of Transient in Starter (Open Transient starter)
            • Size of each part of Star-Delta starter
            • Motor Starting Characteristics of Star-Delta Starter
            • Advantages of Star-Delta starter
            • Disadvantages of Star-Delta starter
            • Features of star-delta starting
            • Application of Star-Delta Starter
            • LESSON 1 WIRING SYSTEM OF SINGLE PHASE DISTRIBUTION BOARD
            • LESSON 2 WIRING SYSTEM OF SINGLE PHASE LIGHTING CIRCUIT
            • LESSON 3ndash WIRING SYSTEM OF SINGLE PHASE POWER CIRCUIT
            • LESSON 4ndash CONDUIT BENDING AND TRUNKING FABRICATION TECHNIQUE
            • LESSON 5 ndashWIRING SYSTEM OF 1 Oslash LIGHTING AND POWER CIRCUIT
              • POWER CIRCUITS
                • LESSON 6 ndash WIRING SYSTEM OF 3 Oslash DISTRIBUTION BOARD
                • LESSON 7 ndash WIRING SYSTEM OF THREE PHASE LIGHTING AND POWER CIRCUIT
                • LESSON 8 INSPECTION AND TESTING OF ELECTRICAL INSTALLATION
                  • CONTINUITY TEST
                    • Polarity Test
                      • Earth Electrode Resistance Test
                      • Earth Electrode Resistance Measurement Method (Figure 86)
                        • Residual Current Device Test
                        • LESSON 9 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (DC)
                        • LESSON 10 ndashWIRING SYSTEM OF RELAY AND CONTACTOR CIRCUIT BOARD (AC)
                        • LESSON 11ndashWIRE THREE UNITS OF 3 PHASE INDUCTION MOTOR TO OPERATE IN SEQUENCE
                        • LESSON 12ndashWIRE FORWARD REVERSE DAHLANDER MOTOR STARTER
                          • LESSON 13 ndash FORWARD REVERSE STAR DELTA STARTER
                          • LESSON 14 ndash WIRE TWO STAGES OF AN AUTOTRANSFORMER STARTER
                          • LESSON 15 ndash WIRE 4 STEPS OF ROTOR RESISTANCE STARTER
                            • a Dead circuit test
                            • b Life circuit test
                            • LESSON 16
                              • TROUBLESHOOTING AND FAULT FINDING OF 3Oslash INDUCTION MOTOR
                              • SELF-ASSESSMENT QUESTIONS