LO1: Plan and Prepare for Motor controller Installation

INTRODUCTION

Control symbols

We use drawings to convey the information about piece of equipment in a form which all those I
nvolvedin its production installation and service will understand Tomake this possible standard d
rawing conventions have been adopted by most companiesn

When you learned to readyou werefirst taught a set ofsymbolsthat represented different soundsThisset ofs
ymbols is called the alphabet. Schematics and wiringdiagrams  are  the  written  language  of  motor  con
trols.Before  you  can  learn  to  properly  determine  the  logicof  a  control  circuit,  you  must  first  lear
n  the  writtenlanguage Unfortunately there  is  no  actual  standardused for motor control symbolsDiffere
nt manufacturers and companies often use their own sets of symbolsfor their in-house schematicsAlso, sch
ematics drawnin other  countries  may  use  entirely  different  sets  ofsymbols  to represent different  cont
rol  components.Although  symbols  can  vary  from  one  manufacturerto  another,  or  from  one country 
to another once youhave learned to interpret  circuit  logic  it is  generallysent by  the  way  they  are  use
d  in  the  schematic Themost standardized set of symbols in the United Stateis  provided  by  the  National 
 Electrical  Manufacturer’sAssociation, or NEMA. Schematic and wiring diagrams are the written langua
geof control circuitsMaintenance electriciansmust  beable to interpret schematic and wiring diagrams to i
nstall control equipment or troubleshoot existing controlcircuits Schematic diagrams are also known as li
ne 
diagrams and ladder diagrams. Schematic diagrams showcomponentsin their electrical sequence without 
regardto  physical  location.Schematics are used  more  thananyother type of diagram to connector troubl
eshoot acontrol circuit.Wiring  diagrams  show  a  picture  of  the  controlcomponents  with  connecting  
wires.  Wiring diagramsare sometimes used to install new control circuits, but
they are seldom used for troubleshooting existing circuits.

Circuit Symbols
The following are the circuit symbols commonly used in motor related schematic diagrams

1
Almaz Boehm polly technic Collage P.by teketel Sintayehu 2012 E.C
 2
Almaz Boehm polly technic Collage P.by teketel Sintayehu 2012 E.C
 17.  Plug (male contact).
18.  Socket (female contact).
19.  Coaxial plug.
20.  Coaxial socket.

50 Push button switch momentary.
51.  Push button, push on/push off (latching).
52.  Lever switch, two position (on/off).

p.by Teketel Sintayehu

3
Almaz Boehm polly technic Collage P.by teketel Sintayehu 2012 E.C
 4
Almaz Boehm polly technic Collage P.by teketel Sintayehu 2012 E.C
 5
Almaz Boehm polly technic Collage P.by teketel Sintayehu 2012 E.C
The circuits drawn for motor control circuits are in two forms :(a) Circuit or schematic diagram

(b) Wiring diagram.

(a) Schematic or Circuit Diagram: While designing a control circuit, the schematic diagram is drawn
first as it is easy, simple, clear and easy to follow for implementation in practical wiring diagram. 'The
diagram drawn below is a schematic diagram for a simple D.OL starter. The main thing which is to be
settled in mind is that practically, the contactor coil and its auxiliary contacts are close to each other but in
schematic diagram, they are at different places .

6
Almaz Boehm polly technic Collage P.by teketel Sintayehu 2012 E.C
Fig. The contactor coil A and auxiliary contact 'a' are practically close together but in control
circuit or schematic diagram, they are at different places. The power contactors, coil and
auxiliary contacts are mounted over a common insulating link.

(b) Wiring Diagram": The wiring diagram is practically implemented design showing
connection

to various components, While designing the control circuit, the schematic diagram is drawn first
and then

on the basis of connections shown on schematic diagram, the power circuit wiring diagram is
prepared showing layout and connections to componen

DESIGN GUIDELINES

1. The supply to relay or contactor coil should commence by pressing start push button.

2. The supply to relay coil should continue through its contactor even if push button is released.

3. The schematic diagram is prepared first.

4. While drawing wiring diagram, mark the layout of components and then make connections
purely on

The basis of schematic diagram. For example, upper terminal of contactor 'a', lower terminal of
off push button and upper terminal of start push button are connected together in the schematic
diagram identify the same terminals in wiring diagram wherever they are, and connect them.

5. The 3 phase supply lines are to be shown horizontal while the power circuit lines are to be
drawn vertical.

6. The movement of contacts and push buttons to be shown from left to right.

7. The main switches and other switches are to be shown in off position.

8. The contactors and, push buttons are to be drawn in non-actuated position.

9. Crossings of lines in the wiring diagram should be minimized. .

10. If there is sequence of operation, the circuit, which is energized, first should be more to the
right.

7
Almaz Boehm polly technic Collage P.by teketel Sintayehu 2012 E.C
11. All letters and numerical should be kept clear of the guidelines. Words may be underlined in
a drawing where preferred.

12. Lettering should be done on the drawing in such a way that it may be read when the drawing
is viewed from the bottom edge or from bottom and right hand edges.

13. The height of letters on the drawing should not be too small or too large. When drawings are
to be reproduced to a smaller scale by photographic process, the size of letters in the original
drawing

Preparing and installing industrial installation components/accessories

Circuit  protection  devices  are  used  to  protect  wires  and  connectors from being damaged by
excess  current flow  caused  by an over current or shortcircuit Excess current causes  excess
heat which causes  circuit protection  to "open  circuit"
Fuses,  fuse  elements,  fusible  links,  and  circuit  breakers  are  used  as  circuit  protection
devices.  Circuit  protection  devices  are  available  in  a  variety  of  types,  shapes,  and  specific
current  ratings.
FUSES
A  fuse  is  the  most  common  protection  device. A  fuse  is  placed  in  an  electrical circuit so  th
atwhen current flow exceeds  the  rating  of  the  fuse  it  "blows" or "blows  out". The  element  in
the  fuse  melts,  opening  the  circuit  and  preventing  other  components  of  the  circuit  from
being  damaged  by  the over current.   The  size  of  the  metal  fuse  element  determines  the
rating.  Remember  excessive  current  causes  excess  heat,  and  it's  heat  and  not  the  current
that  causes  the  circuit  protector  to  open.  Once  a  fuse  "blows"  it  must  be  replaced  with  a
new  one.
motors having starting current higher than twice of their normal full load current the rating of
the fuse should be based on motor starting current should be kept high enough to permit
legibility after reproduction.

.Selection of HRC Fuses for Motor Panels The HRC (High Rupturing Capacity) fuse links are
used on all industrial panels in main switches. The conventional rewirable fuse links are now out
dated hence not preferred. A protective device must withstand maximum possible destructive
energy of expected short circuit. If fault current exceeds the capability of protective device, the
device may itself rupture. A current limiting protective device cuts off a short circuit current in

8
Almaz Boehm polly technic Collage P.by teketel Sintayehu 2012 E.C
less than one half cycle. The fuse links selected should have a current rating not less than the
normal full load current

CIRCUIT BREAKER CONSTRUCTION (MANUAL TYPE)

A  circuit  breaker  basically  consists  of  a  bimetal  strip  connected  to  two  terminals  and  to aco
ntact  in  between. Manual  circuit  breaker  when  tripped  (current  flow  beyond  its  rating)  willo
pen  and  must  be  reset  manually, These  manual  circuit  breakers  are  called non-cycling"circuit  
breakers.

CIRCUIT BREAKER OPERATION (MANUAL TYPE)
The  circuit  breaker  contains  a  metal  strip  made  of  two  different  metals  bonded  together
called  a  bimetal  strip.  This  strip  is  in  the  shape  of  a  disc  and  is  concaved  downward.  Whe
n heat  from  the  excessive  current  is  higher  than  the  circuit  breaker  current  rating  the  two
metals  change  shape  un evenly.  The  strip  bends  or  warps  upwards  and  the  contacts  open  to
stop  current  flow.  The  circuit  breaker  can  be  reset  after  it  is  tripped
Selection of A circuit breaker is equipment that breaks a circuit either manually or
automatically under all conditions at no load, full load or short circuit.Operating Principle
Two contacts called electrode remains closed under normal operating conditions. When

9
Almaz Boehm polly technic Collage P.by teketel Sintayehu 2012 E.C
fault occurs on any part of the system, the trip coil of the circuit breaker gets energized and
contacts are separated. Circuit Breaker ratings 7.5, 10, 14, 18, 20, 22, 25, 30, 35, 42, 50, 65,
85, 100, 125, 150, or 200kA

 Overload Relay
A relay is an electromagnetically operated switch. It consists of  an operating coil wound
around an electromagnet pole piece, a moving armature and one or more sets of contacts.When
a voltage of the correct value is applied across the coil terminals the resulting current flow
through the coil produces a magnetic field similar to a bar magnet.The armature is attracted by
the magnetic field and so moves a small distance.This movement operates the contact(s). The pol
e piece is magnetically soft. When current flow through the coil ceases the pole piece loses
its magnetism and the armature returns to its deenergised position. This allows the contact(s)
return to the de-energized or normal

There are two types of overload device in use;

 The thermal overload relay
 The magnetic overload relay
The thermal overload relay is the more popular type and is the only one covered in Phase 2.
type of thermal overload relay.
it is suitable forthe protection of amotor with a Full Load Current of any value from 1.6 Amps to 
2.5 Amps. Interference with This value can be setusing the current range adjustment. It also feat
ures a stop button, a hand / auto reset button and a test button. 
It has one N/O and one N/C auxiliary contact. When installed and properly adjusted it may be
sealed to prevent / monitor any un authorized settings.

10
Almaz Boehm polly technic Collage P.by teketel Sintayehu 2012 E.C
 Bimetallic
strip

The three pins protruding from the top are connected directly into the outgoing terminals of acon
tactor. Two of these pins are adjustable so that they can be matched up to a number of
Different size contactors. See underneath pins for this information.
The overload relay may also be installed using a terminal block for separate mounting. Againthe 
pins are adjusted to suit the terminal block. See Figure 

Operation of Thermal Overload Relay
A thermal overload relay works on the principle that, current flowing through a conductor
produces  heat.  If  the  current  is  doubled  in  value  the  amount  of  heat  produced  will  be
quadrupled. 
The current taken by a three phase motor is passed through a set of three small
heater elements. One heater is wrapped around each of the three bi-metal strips as shown in
Figure 

Supply
Terminals Trip Levers

Bi-metal Load

11
Almaz Boehm polly technic Collage P.by teketel Sintayehu 2012 E.C
 Insulation

Heater
Element Terminal

STRIP
The operation of the thermal overload relay is as follows:
Under normal conditions the heat produced by the heater elements is just balanced by the heat
lost from them to the surroundings and consequently there is no effect on the bimetal strips.When 
an overload current flows, more heat will be produced by the heater elements, resultingin 
further heating of the bimetal strips, thus causing them to bend more. This bending of the bi-
metal strips changes the position of the trip lever, which causes the auxiliary contacts to change
over.The  N/C  contact  opens  and  is  used  to  disconnect  supply  from  the  contactor  coil,
There by disconnecting the supply from the motor. The N/O contact closes and is generally used
to supply a signal lamp to indicate that the overload relay has tripped.

Reasons for Overload Protection

As stated earlier, excess current flowing through a motor winding will cause overheating. Thisin 
turn will result in damage to the winding insulation.

 If this occurs the motor is described asbeing “burned out” and must be rewound or replaced.Her
e are some of the reasons why motors burn out:

No overload protection Incorrect overload relay fitted Incorrect overload relay setting

The main functions of thermal type overload relays are to prevent burn out of windings due to

Overloading or single phasing. Overloading applies to all motors, while single phasing only
applies to three phase motors. 
12
Almaz Boehm polly technic Collage P.by teketel Sintayehu 2012 E.C
Overloading
When the load is increased on an induction motor the rotor speed reduces and the current taken
by the motor increases.When this current rises above the motor Full Load Current, the motor is
considered to be overloaded. Generally speaking, motors can cater for a 110 - 120% overload.Co
nsequently overload devices are calibrated to allow for this. An overloadrelay set at 10Amps will 
trip after a time delay, on a load current of 10 + 15% = 11.5 Amps.A thermal overload relay will 
allow for the starting current of an induction motor. It takes time
to heat the bimetal strips. This provides a time lag to allow the starting current flow for
a sufficient period of time to get the motor up to full speed.
Low value overloads will be detected and acted upon after a period of time.
Higher value overloads will be detected and acted upon in a shorter time.A relay is an  electro-
magnetically operated switch.  It consists of  an  operating  coil  wound around an electro
magnet pole piece, a moving armature and one or more sets of contacts. 
When a voltage of the correct value is applied across the coil terminals, the resulting current flow
through the coil produces a magnetic field similar to a bar magnet. The armature is attracted by
the magnetic field and so moves a small distance.
This movement operates the contact(s). The pole piece is magnetically soft. When current flow
through the coil ceases, the pole piece loses its magnetism and the armature returns to its de-
energised position. This allows the contact(s) return to the de-energised or normal state.

Time Delay Relay

A time delay relay is a relay that stays ON for a certain amount of time once activated. This time
delay relay is made up of a simple adjustable timer circuit which controls the actual relay. The
time is adjustable from 0 about certain seconds or hours with the parts specified. Fig.1.6 and
Fig.1.7 shows analog and digital display relays.

13
Almaz Boehm polly technic Collage P.by teketel Sintayehu 2012 E.C
Digital display
time delay relay
Figure 1.6. Analog display relays Figure 1.7.Digital display relays

2. Contactors
-A contactor is an electromagnetically driven switch applied for electrical power engineering.

14
Almaz Boehm polly technic Collage P.by teketel Sintayehu 2012 E.C
 15
Almaz Boehm polly technic Collage P.by teketel Sintayehu 2012 E.C
Contactors may have different arrangements of contacts. One has to differentiate between
primary contacts (main contacts) and secondary contacts (auxiliary / control contacts).as shown
in the fig.2.1.

16
Almaz Boehm polly technic Collage P.by teketel Sintayehu 2012 E.C
 Coils for different
voltages

17
Almaz Boehm polly technic Collage P.by teketel Sintayehu 2012 E.C
 Main contacts

Auxiliary contacts

Figure 2.3.A contactor with two one NO and one NC auxiliary contacts.

You can control contactor circuits by timers with on –or off delay. This is important for
motor control circuits like star-delta start circuit.

Difference between Contactor and Relay

18
Almaz Boehm polly technic Collage P.by teketel Sintayehu 2012 E.C
  Since a contractor is required for a higher load, a relay is always cheaper than a
contractor.

 A relay is normally used in appliances below 5KW, while a contractor is preferred

when the appliance is heavier.

 A relay is used only in control circuit while a contactor can be used in both
control and power circuits.

 In general contractors are little slower than relays

 Contactor is so designed that it can be repaired while it is not normally done in

the case of relays.

THEIR ARE DIFFERENT TYPES OF INDUSTRIAL SWITCHS DEVICE

 Toggle  Switches
A  manually  operated  switch  is  one  that  is  controlled  by
hand.  examples of manually operated switches. A toggle switch
uses a mechanical lever mechanism to implement a posi-
tive snap action for switching of electrical contacts. 

 Selector  Switch
The difference between a push button and selector switchis the operator mechani
ma selector switch operator isrotated(instead of pushed) to open and close contact
s ofthe  attached  contact  block Switch  positions are established by turning  the  op
erator knob right or left Theseswitches may have two or more selector positions
witheithermaintained contact positionor spring return to given momentary
contact operationan. example  of  a  three-position selector  switch used to select 
three differento
perating modes for control of a pump motor The operationof the circuit can be su
mmarized as followsIn the  HAND position the pump can be started by
closing the manual control switch. 
It can be stoppedby opening the manual control switch or selectingthe OFF positi
on of the selector switch.
The liquid level switch has no effect in either the HAND or OFF position
When AUTO is selected, the liquid-level switch controls the pump
At a predetermined level theliquid level switch will close,starting the pump At
another predetermined level, the liquid level switch will open stopping the pump.
The selector switch contact position and resultant state are identified
by means of the table shown Contacts are marked as A and B, while positions are

Drum  Switch

A drum switch consists of a set of moving contacts and

19
Almaz Boehm polly technic Collage P.by teketel Sintayehu 2012 E.C
a  set  of  stationary  contacts  that  open  and  close  as  the
shaft  is  rotated.  Reversing  drum  switches  are  designed
to start and reverse motors by connecting them directly
across   the   line.  The   drum   switch   may   be   used   with
squirrel-cage motors; single-phase motors designed for
reversing service; and series, shunt, and compound DC
motors.
.Reversal of the direction of rotation is accomplished by
interchanging  two  of  the  three  main  power  lines  to  the
motor. 
Note  that  the  drum  switch  is  used
only as a means for controlling the direction of rotation
of  the  motor  and  does  not  provide  over current  or  over-
load protection. A good rule for most motors is that they
should  be  allowed  to  come  to  a  complete  stop  before
you reverse their direction.
 Limit  Switches
A mechanically operated switch is one that is controlled
automatically  by  factors  such  as  pressure,  position
Limit  switches  are  designed  to  operate
only when a predetermined limit is reached, and they are
usually actuated by contact with an object such as a cam.
These  devices  take  the  place  of  human  operators.  They
are often used in the control circuits of machine processes
to govern the starting, stopping, or reversal of motors.
Limit  switches  are  constructed  of  two  main  parts:  the
body and the operator head (also called the actuator). The
body  houses  the  contacts  that  are  opened  or  closed  in

 Pressure  Switches
Pressure  switches  are  used  to  monitor  and  control  the
pressure of liquids and gases. They are commonly used to
monitor a system and, in the event that pressure reaches a
dangerous level, open relief valves or shut the system down.
The three categories of pressure switches used to activate
electrical contacts are positive pressure, vacuum (negative
pressure), and differential pressure. 
Pushbutton  Switche
Push button switches are commonlyused in motor control applications
to start and stop motors as well as to controland over ride process functions a push button operates by
pressing a button that opens or closes contacts Push button commonly
used types of pushbutton symbols and switching action. Abbreviations N.O(normally open) and
N.C (normally closed) represent the state of  the  switch
contacts when the switch is not activated The N.O. push
button makes a circuit when it is pressed and returns to its open position  when the button is released
The N.Cpushbutton opens the circuit when it is pressed and returns tothe closed position when the butto
n is released button makes a circuit when it is pressed and returns to its
open position when the button is released The N.C push
button opens the circuit when it is pressed and returns tothe closed position when the button is released

20
Almaz Boehm polly technic Collage P.by teketel Sintayehu 2012 E.C
With a  break make pus hbutton the top section contacts are  N.C  and  the bottom section contacts are  
N.O.When the button is  pressed the bottom contacts are closed.

Start Button
A start button consists of a green coloured actuator, which when pressed operates a normally
open contact. On pressing the green actuator the normally open contact will close. These are
fitted on the panel door via a mounting collar. The actuator is fitted through a suitable hole in
the panel door. A rubber washer is used on the outside to provide ingress protection. The
actuator is locked into the collar. The collar is secured to the panel door by a screw. This action
compresses the rubber seal on the actuator. Finally the contact block is simply clipped on to the

clor indicato seal Collar

Actuator Rubber Mounting

Stop Button
A stop button consists of a red coloured actuator, which when pressed operates a normally
closed contact. On pressing the red actuator the normally closed contact will open.
See Figure 

clor indicato seal collar

21
Almaz Boehm polly technic Collage P.by teketel Sintayehu 2012 E.C
 Actuator Rubber Mounting

Emergency Stop Button
This is an emergency stop button and it differs from a standardstop button as follow
s:

It has a large, easy to operate, mushroom shaped actuator.
 This actuator must be mounted on a yellow background.
 When operated, the actuator latches in the “Off “ position.
 The actuator is released by twisting the mushroom shaped head.

WHAT IS ELECTRICAL CONDUIT?

An electrical conduit is a purpose-designed electrical raceway system used for protection and routing of
electrical wiring. Electrical conduit may be made of metal, plastic, fiberglass, or even fired clay. Flexible
conduit is available for certain applications. Conduit is generally installed by electricians at the site of
installation of electrical equipment and/or building electrical systems. Its use, form, and installation
details are often specified by wiring regulations, such as the NEC and/or local electrical building codes.

Conduit systems are classified by the wall thickness of tubing, mechanical stiffness of the tubing, and the
material. Tubing with thicker walls in the same material offers better protection from impact, but
increases the weight and cost of the conduit, and also increases labor cost to install the system. Conduit
is primarily used to protect insulated electrical conductors from damage or the environment. In
addition, metallic types of conduit may also be used to function as an electrical bond from one point to
another. Typically, separate conductors are pulled through conduit and terminated in junction boxes or
other types of enclosures.

22
Almaz Boehm polly technic Collage P.by teketel Sintayehu 2012 E.C
  The following is a description of the different types of conduit used in these
electrical systems.
Electrical Metallic Tubing (EMT) Electrical Metallic Tubing (EMT), sometimes referred to as
“thin-wall conduit”, is commonly used instead of Intermediate Metal Conduit (IMC), Galvanized Rigid
Conduit (GRC), or Rigid Metal Conduit (RMC), as it is less costly, lighter, and easier to install. However,
EMT cannot be threaded due to its thin wall thickness. Lengths of EMT conduit are connected to each
other, and to equipment with setscrew or compression-type conduit fittings. Like GRC and RMC, EMT is
more common in commercial and industrial buildings than in residential applications. EMT is generally
made of zinc galvanized steel, though it also may be specified in aluminum or stainless steel. EMT sizes
of 2½" and larger have the same outside diameter as corresponding sizes of RMC.

Intermediate Metal Conduit (IMC)

Intermediate Metal Conduit (IMC) is medium walled  tubing, heavier  than EMT but lighter

than RMC or GRC, and  typically  made of zinc plated  steel.
It may be threaded or used with setscrew or compression fittings.

Galvanized Rigid Conduit (GRC)
Galvanized Rigid Conduit (GRC) is galvanized steel tubing, similar to RMC, with a hot
dipped galvanized coating which gives it a higher corrosion resistance than standard RMC.It 
is commonly specified for industrial applications

23
Almaz Boehm polly technic Collage P.by teketel Sintayehu 2012 E.C
Rigid Nonmetallic Conduit (RNC)
Rigid Non metallic Conduit (RNC) is non-metallic, un threaded tubing. This is also a
generic term for PVC (polyvinylchloride) conduit.
RNC is the lightest in weight compared to otherrigid conduit materials, and usually lower in cost than o
ther forms of conduit. 
In North America, itis available in three different wall thicknesses (SCH 80, SCH 40, & Type TC or 
Type A), with thethinwall variety only suitable for embedded use in concrete, and heavier grades su
itable fordirect burial and exposed work. The various fittings are also made from PVC. The plastic
material resists moisture and many corrosive substances, but since the tubing is noconductive, an e
xtra bonding (grounding) conductor must be pulled into each conduit. PVCconduit may be heated and bent in 
the field. Joints to fittings are made with slipon, solventwelded connections, which set up rapidly after ass
embly, and attain full strength in about oneday. Since slipfit sections do not need to be rotated during a
ssembly, the special union fittingsused with threaded conduit (i.e. “ThreePiece” Couplings) are not req
uired. Since PVC conduithas a higher thermal coefficient of expansion than other types, long runs mus
t be installed withexpansion couplings to allow for expansion and contraction of each run.

Flexible Metallic Conduit (FMC)
Flexible Metallic Conduit (FMC) (also known as “Greenfield’) is made through the coiling of a self
interlocked, ribbed strip of aluminum or steel, forming a flexible, hollow tube through
which insulated conductors are pulled. FMC is used primarily in dry areas where it would be
impractical to install EMT or other non flexible conduit, yet where metallic strength to protect
conductors is still required. The flexible tubing does not maintain any permanent bend. Cutting

24
Almaz Boehm polly technic Collage P.by teketel Sintayehu 2012 E.C
FMC requires a specialized hand tool with a rotary abrasive disc to create a small incision in to
the ribbing so that a twisting motion separates the segments. 

Liquid tight Flexible Metal Conduit (LFMC)
Liquid tight Flexible Metal Conduit (LFMC) is a non metallic and liquid tight  jacket (usually PVC)
covering a flexible metal interior. The metal interior is similar in construction to FMC.

Liquidtight Flexible Nonmetallic Conduit (LNFC)
Liquid tight Flexible Non metallic  Conduit  (LNFC)  “TypeB”  refers  to  several  types  of  flame
resistant, non metallic  tubing.
Interior surfaces may be smooth or corrugated. There may or maynot be integral reinforcement
within the conduit wall.  

Electrical Nonmetallic Tubing (ENT)
Electrical Non metallic Tubing (ENT) (slang: “smurf tube”)  is  thin-walled, corrugated 
tubing that  is  moisture resistant  and  flame  retardant.
It is extremely flexible and can bend easily  by hand. 
It is not threaded due to its shape and the plastic fittings are specially designed to
interlock with the special corrugated shape. It is typically used in concrete work as well as
commercial building systems.

25
Almaz Boehm polly technic Collage P.by teketel Sintayehu 2012 E.C
 LO – 02 Request materials, tools and equipment
Information Sheet – 1 Learning guide 1

Request materials, tools and equipment

Selecting the best instrument for the laboratory is a very important part of equipment
management. Some criteria to consider when selecting laboratory equipment are listed below.

 Why and how will the equipment be used? The instrument should be matched against the
service the laboratory provides
 What are the performance characteristics of the instrument? Is it sufficiently accurate and
reproducible to suit the needs of the testing to be done
 What are the facility requirements, including the requirements for physical space?
 Will the cost of the equipment be within the laboratory’s budget?
 Will reagents be readily available?
 Will reagents be provided free of charge for a limited period of time? If so, for how long?
 How easy will it be for staff to operate?
 Will instructions be available in a language that is understood?
 Is there a retailer for the equipment in the country, with available services?
 Does the equipment have a warranty?
 Are there any safety issues to consider? If the decisions about purchasing are made
outside the laboratory, for example by a central purchasing body, the laboratory manager
should provide information that will support selecting equipment that will best serve the
needs of the laboratory. In areas where there are national programs for purchasing
standard equipment, the laboratories of the country should have some input to decisions.
In addition, in areas where donors are likely to provide some of the equipment that is
used, laboratory management should have input into choice of equipment. If this is not
possible, management should consider declining equipment, if inappropriate for
laboratory needs.

26
Almaz Boehm polly technic Collage P.by teketel Sintayehu 2012 E.C
LO – 03 inspect electrical materials and tools

Information Sheet – 1 Learning guide 4

Electrical inspectors who issue the work permit for your wiring project will also visit your home to

review the work. Make sure to allow time for these inspections as you plan the project. For most  projects,

inspectors make two visits.
1,The first inspection, called the rough in, is done after the cables are run between the boxes  but before
the insulation, wallboard, switches, and fixtures are installed

2,The second inspection called the final is done after the walls and ceilings are finished and all

electrical connections are made.When preparing for the rough in  inspection, make
sure the area is neat. Sweep up  saw dust and clean up any pieces of scrap wire or cable insulation. 
Before inspecting the boxes and cables, inspectors will check to make sure all plumbing and other mechanical work
is completed. Some electrical inspectors will ask to see  your  building  and  plumbing  permits.
At the final inspection, inspectors check rando boxes to make sure the wire connections are correct.
If they see good work man ship at the selected boxes,the inspection will be over quickly. However, if they
spot a problem, inspectors may choose to inspect every  connection.
Inspectors have busy schedules, so it is a good idea to arrange for an inspection several days in advance. 
When you apply for awork permit, make sure you understand what the
inspectors will look for during inspections.You cannot put new circuits into use legally until
an inspector approves them at the final inspection. Ifyou have planned carefully and done your work well,
electrical inspections are routine visits that give you confidence in your own skills.

27
Almaz Boehm polly technic Collage P.by teketel Sintayehu 2012 E.C
 Equipment/ Daily User Formal visual Combined inspecti
environment visual checks inspection on
and test
Power leads, Exte Yes As per category As per category
nsion used with  used with below
leads, plugs and  below
cables.

Heavy industrial us Yes Yes, Yes,

e,  high Weekly 6-12 months
risk of equipment d
amage,
e.g. circular saws
and. angle grinders.
Residual Current D Yes Yes, Yes,
evices (RCDs) Functional  Test Weekly 6-12 months
(socket outlet &
portable RCDs)

Light industrial use,  Yes Yes, Yes,

e.g.bench mounted  6 months 6-12 months
dagnostic
and test equipment.

Earthed equipment Yes Yes, Yes,

(Class1): e.g. electr 6 months-1 year 1-2 years
ic  kettle
some floor cleaners

Hard wired equip Yes Yes, Yes,

ment:cooker, engi 1 year 1-5 years.
neering
workshop machin
es (e.g.lathe or po
wer-press),

Inspection and Testing of Electrical Equipment/Systems

User Visual Checks
User checks should include but not be limited to checking for:
• damaged, poorly maintained or poorly installed plugs or cables;
• correct connectors used to join cables (no twisted wires or taped joints);
• incorrect use of extension leads (e.g. two or more connected together)
• signs of scorching or burn marks;
• loose wires or missing or damaged insulation;

28
Almaz Boehm polly technic Collage P.by teketel Sintayehu 2012 E.C
• damaged equipment casing;
• correct marking (e.g. in-date test labels).

Formal Visual Inspections

This does not have to be undertaken by a qualified electrician. Visual inspections can be carried
out by a competent member of staff provided they have been given appropriate training and have
acquired sufficient experience. A visual inspection must be conducted with the equipment
isolated, and should ensure that:
• There is no damage e.g., cuts and abrasions (apart from light scuffing) to any cable covering; •
there is no damage to any plug e.g. the casing is not cracked or pins are bent or misaligned;
• The outer covering (sheath) of the cable is securely gripped where it enters the
plug or the equipment, and that the colored insulation of the internal wires are not visible without
removing the plug or equipment cover;
• the equipment shows no sign of having been used in an environment where it is not suitable
(e.g., wet or muddy);
• there is no damage to the outer cover of the equipment, e.g. obvious loose parts, screws missing
or cracks in the casing;
• There are no signs of overheating (burn marks or staining);
and may also include checking that:
• the cable terminations are secure and the correct polarity
the correct rated fuse is fitted.
Testing
Formal testing of electrical equipment shall only be performed by a competent person (having
the required knowledge, training and experience). A person not skilled in electrical work but
trained in the use of and routinely using a simple ‘pass/fail’ type of portable appliance tester
(PAT) and the knowledge to calculate the correct fuse rating may be adequately competent for
testing portable equipment; providing the appropriate test procedures are rigorously followed and
acceptance criteria are clearly defined. The testing of any equipment/system that is hard-wired to
an electrical supply above Extra Low Voltage must be carried out by a competent qualified
electrician and in accordance
Recommended Initial Inspection/Testing Intervals For Electrical Equipment
Risk assessments should identify changes to the above need and frequency of inspectionand testing 
depending on the equipment type, its usage and the operating environment(some extra low voltage 
specialist equipment will require daily user checks and frequentformal inspections, e.g. Ex rated t
orches).  Where the inspection/testing regime is pickingup a number of faults then consideration s
hall be given to increasing the frequency ofinspection and testing.
Formal inspection and testing records should includes The description of the piece o
f equipment;
 An asset number or equipment serial number (unique identifier)
 Location of the equipment;
 Date of next inspection/test
 Inspection/test Phass or Fail;
 Details of any inspection/test failures.

29
Almaz Boehm polly technic Collage P.by teketel Sintayehu 2012 E.C
 LO-4 Assemble electrical motor controller

Information Sheet – 1 Learning guide 1

INTRODUCTION

MOTOR STARTING
All motors must have a control device to start and stop the motor called a “motor controller”. A
motor controller is the actual device that energizes and de-energizes the circuit to the motor so
that it can start and stop.
Motor controllers may include some or all of the following motor control functions:
starting, stopping, over-current protection, overload protection, reversing, speed
changing, jogging, plugging, sequence control, and pilot light indication.
Controllers range from simple to complex and can provide control for one motor,
groups of motors, or auxiliary equipment such as brakes, clutches, solenoids, heaters,
or other signals.
Motor Starter
The starting mechanism that energizes the circuit to an induction motor is called the “starter” and
must supply the motor with sufficient current to provide adequate starting torque under worst
case line voltage and load conditions when the motor is energized.
• There are several different types of equipment suitable for use as “motor starters” but only two
types of starting methods for induction motors:
1. Across the Line Starting
2. Reduced Voltage Starting Across the Line Starting of Motors
Across the Line starting connects the motor windings/terminals directly to the circuit voltage
“across the line” for a “full voltage start”.
• This is the simplest method of starting a motor. (And usually the least expensive).
• Motors connected across the line are capable of drawing full in-rush current and
developing maximum starting torque to accelerate the load to speed in the shortest
possible time.
• All NEMA induction motors up to 200hp

30
Almaz Boehm polly technic Collage P.by teketel Sintayehu 2012 E.C
(horsepower,) and many larger ones, can withstand full voltage starts. (The electric
distribution system or processing operation may not though, even if the motor will). Across the
Line Starters

There are two different types of common “across the line” starters including
1. Manual Motor Starters
2. Magnetic Motor Starters

4.1.1 Installing manual motor starter for 3-phase squirrel cage motors on
an installation chassis
Manual Motor Starters
A manual starting is a motor controller whose contact mechanism is operated by mechanical
linkage from hand operated ,toggle or push button a thermal unit a direct acting over load
mechanism provide motor over load protection basically manual starting is ON _off switch
overload relay
 Manual starters are generally used on small machine fans and blowers

Fig1 Manual motor

A manual motor starter is package consisting of a horsepower rated switch with one set
of contacts for each phase and corresponding thermal overload devices to provide motor
overload protection.
• The main advantage of a manual motor starter is lower cost than a magnetic motor

31
Almaz Boehm polly technic Collage P.by teketel Sintayehu 2012 E.C
starter with equivalent motor protection but less motor control capability.
• Manual motor starters are often used for smaller motors - typically fractional
horsepower motors but the National Electrical Code allows their use up to 10

4.2 Installing magnetic contactors

MAGNETIC CONTACTOR MOTOR STARTERS
Amagnetic motor starter is a package consisting of a contactor capable of opening and closing a 
set of  contacts  that  energize  and  deenergize  the  circuit  to  the  motor  along  with  additional 
motor over load  protection  equipment.
magnetic starters are used with larger motors (required above 10 horsepower) or where greater
motor control is desired.the main element of the magnetic motor starter is the contactor, a set of c
ontacts operated by an  electro magnetic  coil.
energizing the coil causes the contacts (a) to close allowing large currentsto be initiated  and
interrupted by a smaller voltage control signal.the control voltage need not be the same as the
motor supply voltage and is often low voltage  allowing  start/stop  controls  to  be  located
remotely from the power circuit

Figure 3  Magnetic Starter
Closing the Start button contact energizes the contactor coil.  An auxiliary contact on the
contactor is wired to seal in the coil circuit.  The contactor deenergizes if the control circuitis 
interrupted, the Stop button is operated, or if power is lost.The overload contacts are arranged so 
an overload trip on any phase will cause the contactortor open and de-energize all phases

32
Almaz Boehm polly technic Collage P.by teketel Sintayehu 2012 E.C
4.2.1 Installing on-off control circuits with magnetic contactors on an
installation chassis

33
Almaz Boehm polly technic Collage P.by teketel Sintayehu 2012 E.C
Motor starts using magnetic contactor

a) Direct-on-line starting (D.O.L).

This is by far the most common starting method. The starting equipment consists of only
a main Contactor and thermal or electronic overload relay as shown in fig.2.4 below.

Figure - 4 Direct-on-line starting (D.O.L).

This stating method is not used for motors with power rating of greater than 5KW.
Thus is due to high starting current and starting torque.

D.O.L-Power and control circuit

34
Almaz Boehm polly technic Collage P.by teketel Sintayehu 2012 E.C
Figure 5 D.O.L starting power and control circuit

As shown in Fig.5 power circuit, when the coil of the contactor energized the contactor closes
the contacts and the motor receives a three phase supply. In the control circuit of separate push-
buttons are provided for energizing and de-energizing a contractor. For starting, a push-button
with an NO contact (S3) and for stopping another push-button with an NC contact (S2) is used.
A normally open (NO) auxiliary contact (-K1-13-14) of the contactor is connected in parallel
with the start push-button S3 so that the contactor should remain energized even when the
pressure on the start push-button is with drown. Thus the contactor would continue to remain
energized by receiving supply through its own contact –K1. Contact –K1 here has been used as a
self-hold -on contact as it holds on the supply even after the pressure on the push-button has been
released. Thus the motor continues to rotate once the start push button has been pressed. For
stopping the motor S2 is pressed. Here –S1 is the emergency switch and –F5 is overload relay for
overload protection.

A) Star -Delta starting principle

35
Almaz Boehm polly technic Collage P.by teketel Sintayehu 2012 E.C
 Figure 6 Star- delta starting contactors, push-buttons, and overload relays

What is Star Delta starting?

 Star Delta starting is when the motor is connected (normally externally from the motor)
in STAR during the starting sequence. When the motor has accelerated to close to the
normal running speed, the motor is connected in DELTA. Pictures 1 and 2 show the two
connections for a series connected three phase motor and fig.2.5 show the overall power
circuit of star-delta.

Why is Star Delta Starting used?

36
Almaz Boehm polly technic Collage P.by teketel Sintayehu 2012 E.C
  Let’s consider an example motor: 120kW, 4 Pole, 380 Volt, Delta connected, 3 Phase, 50
Hz. To truly grasp the differences between these two starting methods, we will list the
values next to each other in table.

Immediately we notice the primary reasons for using star delta starters on electric motors:
 The starting power is reduced from 98 kW to 33 kW (by approximately 67%).
 The starting current is reduced from 1495 A to 500 A (by approximately 67%).
 Because the motor is not intended to actually run in this connection, the reduction in full
load speed, power factor and efficiency is not significant for this discussion. The reason
for these 67% changes becomes clear when we examine the phase voltage on the motor,
we see that the phase voltage when the motor is connected in Delta is 380 Volt.
 When the motor is however connected in Star, the Phase Voltage will be 219.3 Volt.
Thus, when the motor is started in the star connection, the phase voltage of the motor is
37
Almaz Boehm polly technic Collage P.by teketel Sintayehu 2012 E.C
 reduced by a factor of √3. The relations for star and delta connections are as listed in a
Table as follow

The reductions in starting current, starting power and starting torques for a reduced Voltage can
each be calculated as follow:

What are the advantages of using Star Delta starting?

- The most significant advantage of using Star-Delta starting is the huge reduction in the starting
current of the motor, which will result in a significant cost saving on cables, transformers and
switch gear.

Power and Control circuit of Star-Delta starting

38
Almaz Boehm polly technic Collage P.by teketel Sintayehu 2012 E.C
Figure 2.7 Power and Control circuit of Star-Delta starting

As shown in the control circuit of fig.2.7 when push-button –S2 is pressed contactor –K3
energized thus, intern makes NO(13,14) of contactor –K3 to close and NC(21,22) to open, as
a result contactor –K1 energized and contactor –K2 de- energized . This helps the motor to run
in star connection. When push-button –S3 is pressed contactor –K3 de-energized, both –K1
and –K2 energized, and the motor operated in delta.

39
Almaz Boehm polly technic Collage P.by teketel Sintayehu 2012 E.C
Figure 8 Star- delta control circuit using timer

As shown in the control circuit of fig.2.8 when push-button –S2 is pressed both contactors –K3
and –K1 energized and the motor runs in star after a pre defined time NC contact of the off delay
timer (-K4T) opens, thus makes contactor –K3 to de-energies and contactors -K2 and -K1 to
energies, and the motor operates in delta.

Reversing a Three-Phase Motor

The rotation of a three phase motor can be reversed by interchanging the connection of any
motor terminals to the supply lines. As shown in the fig.2.7, two separate contactor are used for
this purpose, one for forward and another for reverse operation. To prevent both the contactors
from being energized simultaneously and causing a short circuit, some preventive methods called
interlocking methods are employed. Two different interlocking methods generally used are
described below

40
Almaz Boehm polly technic Collage P.by teketel Sintayehu 2012 E.C
Figure 2.9

Power and Control circuit of motor reversing

Push button interlocking Push-button interlocking is one of the methods of preventing two
contactors from being energizing simultaneously. As shown in fig.2.9 power circuit, through
contactor –K1, the motor is fed with a three phase supply for forward rotation whereas through
contactor–K2, the motor is fed for reverse direction rotation. Both the NO and NC contacts of the
forward and reverse Push-button have been used. When the forward Push-button (-S3) is
pressed, contactor –K1 get energized by getting supply through the NC contact of the reverse
Push-button (-S2). The contactor remains energized even when the pressure on the Push-button
is withdrawn as the NO contact (-K1:13-14) of the contactor –K1 is now closed (this is called
self-hold-on contact). When the reverse Push-button (-S2) is pressed contactor –K1 gets de-

41
Almaz Boehm polly technic Collage P.by teketel Sintayehu 2012 E.C
energized first and then contactor –K2 B gets energized. This ensures that it is not possible to
energies both the contactors simultaneously.

Auxiliary contact interlocking In this method, interlocking is done by connecting a normally

closed auxiliary contact of the forward contactor in series with the coil of the reverse contactor
and vice versa, as shown in fig2.9, thus preventing simultaneous energization of both the
contactors. When the Push-button -S3 is pressed, contactor –K1 get energized and provides a
three-phase supply to the motor for forward operation. When pressure on the Push-button -S3
is released the contactor remains energized because of the closing of the self hold on contact -
K1. It should be noted that when a contactor –K1 is energized it is not possible to energies
contactor -K2 because NC of contactor –K1 is used in contactor -K2. Similarly, when contactor
–K2 is energized it is not possible to energized contactor –K1 because NC of contactor –K2 is
used in contactor –K1. In this circuit changing the direction of the motor is achieved either by
using the stop push button in between or by using push-buttons –S2 and –S2. It is necessary to
stop the motor before receiving its direction of rotation. The motor stops running when stop
push-button (–S1) is pressed.

Sequence start of motors

Sequence control of motors is required in situations where it is necessary to start a particular
motor first before the second motor can be started. This type of control is necessary where one
machine, before starting must have all its auxiliary equipments operating. For example in a
grinding machine, the auxiliary equipments such as the coolant pump and the lubricant pump
should start operating before the rotation of the grinding wheel.

42
Almaz Boehm polly technic Collage P.by teketel Sintayehu 2012 E.C
Figure 2.1.1 power and control circuit of sequence start of two motors

Let us consider the operation of two motors one (-K1) and two (-K2) in sequence. The condition
is such that it should not be possible to start motor two unless motor one is first started. The
control circuit is shown in fig.2.1.1 It is to be noted that contactor –K2 has been connected to the
supply through –K1:23, 24 NO contact of contactor –K1. Hence, unless contactor –K1 is
energized, which closes –K1:23, 24 NO contact, it is not possible to energies contactor –K2 by
pressing Push-button S2. In the same manner it should not be possible to stop motor one unless
motor two is first stopped. Hence contactor –K1 has been connected to the supply through –
K2:13, 14 NO contact of contactor –K2 it is not possible to de-energize contactor –K1 by
pressing Push-button S4.

43
Almaz Boehm polly technic Collage P.by teketel Sintayehu 2012 E.C
 Self check 1(you have to prepare self Give short answer
check questions to measure the fact of
the information sheet )

Name: ____________________ Date: _________________

Directions: Answer all the questions listed below.

PART I TRUE/FALSE

If the statement is correct write TRUE if the statement is in correct write FALSE

_______1. Engineering drawing is entirely a graphic language

________2. Construction lines are used for projecting or transferring locations from one view to
the other and for Construct drawings.

Answer key: - 1) TRUE 2) FALSE

44
Almaz Boehm polly technic Collage P.by teketel Sintayehu 2012 E.C
 Operation Sheet 1 Sectioning the solid objects
PURPOSE: - after
performing this operation
the trainee’s should be able to perform sectioning of solid objects.

Conditions: -

EQUIPMENT AND TOOLS: - set squares, fixer, t-square, brush, drawing board,

MATERIALS: - pencil, lead, paper, eraser,

PROCEDURE:

 A sectional view is obtained by imagining the object, as if cut by a cutting plane and the Portion
between the observer and the section plane being removed.
 The next Figure1a shows an object, with the cutting plane passing through it and Fig.1b the two
halves drawn apart, exposing the interior details

Figure 1

45
Almaz Boehm polly technic Collage P.by teketel Sintayehu 2012 E.C
PRECAUTIONS: - assume as you have cutting a solid object.

QUALITY CRITERIA: - the trainee’s should be able to perform full sectioning of solid objects by any direction
of cut.

LAP Test 1( learning

activity performance or
equations prepared to
Practical Demonstration
measure the performance
of individuals in the
operation sheet )

Name: ___________________________ Date: ______________________

Time started: ________________ Time finished: _______________

Instruction:
1. Show the isometric view of a shaft support
2. Section the views from the front,
3. The view from above and
4. The view from the right.

46
Almaz Boehm polly technic Collage P.by teketel Sintayehu 2012 E.C
Name: ___________________________ Date: ______________________

Time started: ________________ Time finished: _______________

Instructions: You are required to perform the following individually with the presence of your trainer.

1. Show how to identify the isometric views/

2. Show the separated views?
3. Show when dimensions are used?

47
Almaz Boehm polly technic Collage P.by teketel Sintayehu 2012 E.C
 48
Almaz Boehm polly technic Collage P.by teketel Sintayehu 2012 E.C
 49
Almaz Boehm polly technic Collage P.by teketel Sintayehu 2012 E.C
 50
Almaz Boehm polly technic Collage P.by teketel Sintayehu 2012 E.C