By Mr Arusei

INDUSTRIAL MACHINE AND CONTROLS

ELECTRICAL MACHINE 2

-Operational principles of direct current motors.

- Operational principles of cross field machine

- Three phase A.C. Motors

Motor enclosure

Content

Operational principles of direct current motors

Series motors

Shunt motors

Compound motors

OPERATIONAL PRINCIPLES OF CROSS FIELD MACHINES

I. The Metadyne
II. Homo polar motor
III. The hysteresis motor
IV. Operation of single phase a.c motors
V. Split phase
OPERATIONAL PRINCIPLE OF DIRECT CURRENT MOTORS

Can be stated as: wherever a current carrying conductor is placed in a magnetic field it
experience a force whose Direction is given by Fleming’s left hand rule

The force F developed in the conductor is given by the relation.

flux density, B, the current flowing, I, and the effective length of the conductor, l, i.e. F = BIl.

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Line of force have a property of tending to shorten themselves so that they may be regarded as
being in tension each conduction will experience a force like that exerted on a stone in a catapult.
Since these conductors are embedded in slots on the armature the latter is caused to rotate.

BACK OR COUNTER E.M.F.

When armature rotate the conductor on it cut the lines of force of magnetic field in which
they revolve thus an e.m.f is induced in the armature. The e.m.f acts in opposition to the
current in the machine and therefore to the applied voltage so that it is customary to refer to
this voltage as the back e.m.f. ( Lenz’s law = direction of an induced e.m.f is such as to
oppose the change causing it which is of course the applied voltage) .

SERIES MOTOR

Have series configuration of field winding and armature where one end of voltage source
connected to field winding and the other to armature .

Initially at start up motor draws a huge amount of current because both armature and
winding are made up of large conductors thus offers minimum resistance to the current
path. The large current through the armature winding yields a strong magnetic field
providing high torque to the armature shaft , thus invoking the spinning action of the
armature .
The motor starts rotating at its maximum speed in the beginning the rotating armature in
presence of magnetic field results in counter e.m.f which limit the current build up in the
series combination of armature and winding .

MOTOR SPEED
In DC series motor a linear relationship exist between the amount of torque produced
and the current flowing through the field winding , the speed further controls the torque of
motor. They do not operate at contact speed. Its varies with change in the shaft load so
speed control of the motor is not easy to put into practice .

SHUNT MOTORS

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Field windings are shunted i.e. connected in parallel to the armature winding of the motor and
both windings exposed to same voltage supply

Torque developed is proportional to armature current the armature winding must be exposed
to an amount of current that is much higher than the field winding thus field winding is
wound with many turns to increase flux linkage I proportional to the torque .

SPEED REGULATION

It has self speed regulation on application of load to the shaft , while running with no load its
speed is constant on application of load on the shaft the speed definitely reduces , and a long
with speed also reduces the back emf with reduction in back e.m.f. it leads to increase in
net voltage the armature current increase consequently , the torque increases , this increase in
torque increases the speed and thus compensating for the speed was on loading .

COMPOUND MOTOR

Falls under category of self existed motor its made up of series field coils S 1S2 and shunt field
coils F1F2 connected to the armature winding .

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forward rotation

reverse rotation

Both the field coils provide for the required amount of magnetic flux that links with the
armature coil and brings about the torque necessary to facilitate rotation at the desired speed ,
it provides better properties of series and short motor since its an Amalgamation of the two .

CROSS FIELD
THE CROSS FIELD PRINCIPLES

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Convectional two-pole DC machine with armature and brushes as shown above,

1] flux along horizontal axis with axis which generate the voltage between the brushes B4 and
B3 on the commutator but no voltage between the brushes B1 and B2 placed along the field
axis for horizontal axis are at right angles .
2] flux a long vertical axis will generate voltage between brushes B1 and B2 placed along
horizontal axis on the commutator but no voltage will be induced between brushes B4 and
B3 placed along the vertical axis .
[3] here above two case have been combined flux along the horizontal axis generate
voltage
interfere with each other thus this device is virtually two machine in one if armature
reaction is negligible or full compensation is provided , although the current are
superimposed in the same armature conductors they can still be considered to have a
scientific existence . this leads to an interconnection between the two system which is
made use of advantageously in machine called cross –field generator .

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THE METADYNE

It is the development of the Rosenberg generator. In the Rosenberg generator no compensation

is provided for armature reaction M.M.F [ magneto motive force ] set up by the load current
as it was essential for giving constant current characteristic. When operating under
appropriate conditions, it is essential to neutral the armature reaction M.M.F set up by the
load current and this is achieved by connecting a compensating winding in series with the
power output brush terminal .

Commutating poles are also required in these machine for satisfactory commutation whereas
no commutation pole is required in the Rosenberg generator for satisfactory commutation.
Fully compensated machine is called AMPLIDYNE and under compensated machine is called
Metaldyne .

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Metadyne is partially compensated thus the opposing flux produced by the control flux, will
control output current which would neutralize most of the control flux and this will control the
output current by suppressing the current through control windings.

Metaldyne have been used to control the aiming of large guns and for speed control in
electric trains in particular the London underground O and P stock.

OPERATION

The first arrangement represents a one –pole cross field machine , in a normal DC machine
the effect of the excitation current generates a flux [A1] which intern generate excitation
current that generates quadrature flux which is at right angle to the exciting flux.

- The current is produced in the armature and the flux that that produces [A2] is again
at right angles to the quadrature resulting in an armature reaction which is partly
compensated by a compensation winding and the compensated portion of the
armature reaction acts in this way.
- As the output current rises, it suppresses its effect of excitation until it reaches a state
where it is just enough excitation to maintain the current. Any further increase would
eliminate the flux which sustain its operation and the current is maintain

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irrespective of the resistance of the load thus acts as a constant current generator
where the current is proportional to the excitation.
- The second diagram shows a machine with no excitation winding but instead a
constant voltage is connected to the quadrature brushes. This produces a flux similar to
the one produced by rotation of the armature in the excitation flux in first example. Input
and output power are same and so the machine transform the constant voltage input
into a constant - current output. This is a generator where the current is proportional to
the excitation.
- Third diagram show a metadyne connected to two separate motors and this
arrangement was used for the control of traction motors on electric trains.

THE HOMOPOLAR MOTOR

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The nail and magnet spin with the nail tip acting as a bearing

PRINCIPLES OF OPERATION

The homopolar motor is driven by the LORENTZ FORCE. Which states that when a
conductor with a current flowing through it is place in a magnetic field which is
perpendicular to both the magnetic field and the current, it experiences a force that provides a
torque around the axis of rotation because the axis of rotation is parallel to the magnetic field
and do not change polarity, No commutation is required for the conductor to keep turning.
This simplicity is most readily achieved with single turn design which makes homopolar
motors unsuitable for most practical applications .

THE HYSTERESIS

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Have a solid smooth cylindrical rotor cast in a magnetic hard cobalt steel (i.e. have wide
hysteresis loop). When this machine is once magnetized in a given direction, it requires a large
reverse magnetic field to reverse the magnetization. The rotation of stator field causes each
small volume of the rotor to experience a reversing magnetic field at the slip frequency
which drives it around its hysteresis loop and the rotor creates torque. As the rotor approaches
synchronous speed and slip goes to zero this magnetizes and aligns with the stator field ,
causing the rotor to lock to the rotating stator field .

SINGLE PHASE A.C MOTOR

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SPLIT PHASE MOTOR

Provides much greater starting torque than shaded pole motor.
It has a secondary start up that is 90 electrical degrees to the main winding always
controled directly between the poles of the main winding and connected to the main
winding by a set of electrical contacts .

Operates subjects to a pulsating magnetic field. The two separate windings wired in tandem
produces a two phase rotating magnetic field. This is due to a difference of impendence. Start
winding has a higher resistance than the running winding and after a few seconds of
rotation a centrifugal switch or timed relay automatically remove the start winding from
the circuit .

CAPACITOR START MOTOR

Have an electrolytic capacitor in series with the start winding to obtain a greater phase angle and
torque. Has two windings i.e. the start and the run. A centrifugal switch or timed relay remove
the start winding from circuit when rotation reach about 75% of the full rotor speed .

Capacitor-start capacitor-run induction motor

The most efficient of the range of single-phase induction motors is the capacitor-start capacitor-
run type. The main feature is that the starting winding is not switched out but is continuously
energized, the only change between starting and running being the value of capacitance. This
change is achieved by using two capacitors and switching one out with the centrifugal switch.

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Shaded-pole induction motor

The shaded-pole type of motor has a stator with salient (projecting) poles and in each pole a
short-circuited turn of copper face is inserted. The alternating flux in the pole face induces a
current in the shading coil which in turn produces an opposing flux. This opposition causes a
slight phase displacement of the fluxes in the two parts of each pole which is enough to start the
rotor turning. As the phase displacement is very small the motor has a very small starting torque,
thus limiting its use to very light loads.

The universal or series motor

The universal or series motor is simply a d.c.-type armature with commutator and an a.c. field. It
is connected as for a d.c. series motor. This motor will operate on an alternating current because
the polarity of the a.c. supply changes on both field and armature; the motor will therefore rotate
in one direction. Reversing is achieved by reversal of either field or armature connections.

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THREE PHASE A.C MOTORS

INDUCTION MOTOR

SQUIRREL CAGE ROTOR

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Now any conductor that cuts magnetic fields at right angle induces an electromotive force
[ EMF] into the coil . It is this same principle that induction motor use to work. The rotor has
hollow slots to which copper bars are drown - in and common circuits made by brass ring
brazed to each end of the copper bars . The stator has three phases Red, yellow, and blue. They
are connected in such a way that they are out of phase by 120o.

WORKING

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Operates on the principles of rotating magnetic field. To obtain momentum, each voltage must
be constantly out of phase by 120o. the physical location of the windings around the stator
adds an influencing factor allowing the magnetic field to gyrate , the speed of the rotating
magnetic field called , the synchronous speed is dependent on the following:

i) Frequency of supply voltage

ii) Number of pairs of poles within stator
- Voltage serving stator must be out of phase by 120o,
- synchronous speed with respect to rotor speed in revolution per minute is given by :
Rpm = f×60/p where,
F = frequency in Hertz
P = pairs of poles
With this the short circuit and copper bars winding which allow the current to flow
throughout the rotor circuit. They will set up their own electromagnetic fields and doing
so will interact with the fields formed within the stator windings. The synchronous speed
of rotating magnetic field has effect of dragging the rotor around with it , the rotor
will rotate at a speed slightly less than synchronous speed ( magnetism has to cut bars
otherwise motor will never function) .

DOUBLE CAGE ROTOR

Close relative to induction motor only that it has two sets of caged rotor bars
instead of one set , one set has a higher resistance than another set thus allowing the
motor to have better starting torque [ over twice much]

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SYNCHRONOUS MOTOR

Relies entirely on rotating magnetic field on its stator windings .

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The rotor takes up role of a permanent magnet, the speed depends on the number of pairs
of poles and frequency of the supply voltage , simple synchronous motor are not self -
starting but manually rotated to the speed of applied electromagnet field . Once done the
rotor will lock in and faithfully pace with the field and so doing maintain a constant speed ,
if the applied load is too great it will find it difficult to pace and will stall and eventually
come to stand still.

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PROCEDURE FOR MAINTENANCE

MAINTENANCE

Maintenance is any activity designed to keep the resources in good working condition or restore them
to operating status. ―Maintenance is a function to keep the equipment or machinery in their normal
operating condition by servicing or repairing or replacing some of the components. Each maintenance
cycle requires four key activities:

1. Completing the requested maintenance action.

2. Retesting the system.
3. Recording details of the activities carried out.
4. Noting any resulting changes made to the system configuration
The primary goals of maintenance program are to:
1. Minimize the number of component failures in the system.
2. Minimize the process impact of failures that do occur and
3. Effectively diagnose the cause of failure and take corrective actions as quickly as possible.
The basic need (Importance) for maintenance of any equipment or machinery is to:
1. Minimize the frequency of interruptions to production by reducing breakdowns.
2. Maximize the production capacity from the given equipment resources.
3. Enhance the safety of work force.

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4. Enhance the service reliability of equipment.

5. Enable to achieve the quality of a product or service through well-maintained equipment.
6. Maximize the useful life of the equipment.
7. Reduce the repair or breakdown cost component in the total production cost.

TYPES OF MAINTENANCE
i) Planned Maintenance
ii) Unplanned Maintenance

PLANNED MAINTENANCE
This is an organized type of maintenance work carried out as per recorded procedures
having control.
Following is the sub-classification of Planned Maintenance.
I. Preventive Maintenance -Scheduled Maintenance
II. Corrective Maintenance -Breakdown Maintenance
III. Predictive Maintenance

PREVENTIVE MAINTENANCE (PM)

The preventive maintenance policy is a system of planned and scheduled maintenance with the
aim of minimizing or preventing breakdowns. Preventive maintenance is ―the utilization of
planned and coordinated inspections, repairs, adjustments, and replacements in maintaining an
equipment or plant. PM inspection and service functions can be classified into three following
groups:
(i) Routine up-keep, i.e., adjustment, lubrication and cleaning of equipment.
(ii) Periodic inspections, i.e., visual inspections, tear down inspections, overhauls,
scheduled replacement of parts, etc.
(iii) Contingent work, e.g., inspection of oil burners while relining a furnace.

Preventive maintenance records:

It is very necessary to keep records because they are the only reliable guides for
measuring the effectiveness of the preventive maintenance programme. Only records
tell us, what the situation at present is and where it is going. Good updated records,
proper filing equipment and adequate clerical help are the backbone of PM
programme.
SCHEDULED MAINTENANCE:
Scheduled maintenance is a stitch-in-time procedure and incorporates
– Inspection
– Lubrication
– Repair and overhaul of equipment. If neglected can result in breakdown. Generally followed
for:
– overhauling of machines
– changing of heavy equipment oils
– cleaning of water and other tanks etc.

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CORRECTIVE OR BREAKDOWN MAINTENANCE

It is one type of planned maintenance and can be defined as ―the practice carried out to
restore the full performance of the equipment that has stopped working to acceptable standards.
Corrective or Breakdown maintenance implies that repairs are made after the equipment is failed
and cannot perform its normal function anymore Quite justified in small factories where:
– Down times are non-critical and repair costs are less than other type of maintenance
– Financial justification for scheduling are not felt

Predictive Maintenance:
It is comparatively a newer maintenance technique.
It makes use of human senses or other sensitive instruments such as:
Audio gauges,
Vibration analyzers,
Amplitude meters,
Pressure,
temperature and resistance strain gauges, etc., to predict troubles before the equipment fails.

TYPES OF MOTOR ENCLOSURE

ENCLOSURE METHOD OF WHERE THEY ARE

CONSTRUCTION USED
WATER PROOF Totally enclosed External situation
instrumentation not water
tight
Water tight Completely water tight Submersed pumps and
marine installation
Protected Live and moving parts are Machine tools and dust-
protected by end shield free average temperature
bolted to the stator yoke , environments.
ventilation parts often
protected by wire mesh
attached to the station
Flame proof A totally enclosed Oil refineries petrol
infrastructure design to pumps and goal mines
safeguard any spent or any flammable or
average within the motor explosive environment
Pipe ventilation A pipe fitted to the air Current works large
intake point of the houses and situations
loading system enable where there is a dusty
clean cool air to circulate environment coupled with
within the motor once high temperature
used the ventilated air
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travel is via a pipe to the

outside atmosphere
D.V.I.P Ventilated ends provided Agricultural situations
with hooded loves laundries and installation
subjected to dropping
moisture
Totally enclosed Mechanical protection for In an industrial situation
both the rotor and stator is where the surrounding
within a ribbed frame this temperature is not too
also helps in cooling an high.
internal plastic or pressed
steel fan provides for
ventilation

INDUSTRIAL POWER PROTECTION AND CONTROLS

PRINCIPLES OF CONTACTOR CONTROL SYSTEM

Contactor is a mechanical switching device capable of making and breaking and carrying
current under normal conditions including operating overload conditions. They are required
to operate more frequently , they have a main circuit and a control circuit . They are designed
according to the method of energizing the control circuit. The types are:
- Electromagnetic device
- Pneumatic type
- Electro-pneumatic type

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Motor protection and control for block making machine (a group of motors)

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CONSTRUCTION AND WORKING OF A CONTRACTOR

Direct on line starting (DOL)

Contactor is electrically operated switch intended for marking and breaking heavy current
when attained by a relay while drawing very little current or by a push button . in DC
circuit contactor mainly of solenoid type which has soft iron plunger that moves inside a
coil of wire. In A.C circuit it comprise of service e shaped laminated sheets with a contactor
coil on the Central leg and is equipped with hinged armature on which main circuit
auxiliary contacts are mounted. Contactors are design to operate automatically even if a
momentary contact is made by the control device i.e. the ON push button which is normally
open (NO) and pressed for a short time for a sec or two then the button is released. the
contactor closes on this momentary impulse and auxiliary contacts remain in closed position
even after ON button is released . the current required to keep the contactor in ON position
is much less than that for closing it . thus the auxiliary hold on contact works to ensure that
the contactor coil does not get hot when operating continuously in the fully closed
position .

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Devices switching more than 15ampere or in circuits rated more than a few kilowatts are
usually called contactors .

CONTACTOR CONTROLCIRCUITS COMPONENTS

PUSH BUTTONS

Contacts of push buttons are usually double break type their contact are operated by a
button. One normally open [NO] and the other normally closed (NC). When pressed by
applying a force the NC contact opens and NO contact closes as long as it held pressed .

It’s provided with a spring that brings back contacts. Green push bottom is used for starting a
device while red is used for stopping.

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RELAY

Operated by magnetism or other mechanism like in thermal relay where a heating coil is
wound on a bimetallic strip the coil carries current flowing through the coil the bimetal
bends consistently and opens a normally closed contact or closes and normally open
contact the opening or closing of the contact of relay driving overload can be utilized in
tripping off the circuit in which this relay has been employed.

JOGGING OR INCHING CIRCUIT

In certain in loads such as crane operation, it is necessary to frequently start the motor
driving the crane for accomplishing small movement every time . Such operation of a motor
is called jogging.
A jogging circuit permits the motor to be energized as long as the jog push-button is kept
pressed thereby providing an instantaneous control of the motor drive .
Drawing

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No hold contact is provided on jog push –button thus the contact coil a will remain en
energized as long as the jog is kept pressed . thus the motor operation controlled by
operator. C is another jogging and using a election switch , selector situation enable to
select either continuous mode of operation or jogging operation .

Drawing

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; control circuit for running and jogging of an induction motor through separate push
buttons .

INTERLOCKING METHODS FOR REVERSING CONTROL

Direction of rotation of three phase induction motor can be reversed by interchanging
connection of any two motor terminals to the supply lines , two separate contactor are used
for this purpose , one for forward and other for reverse operation . to prevent both
contractors from being energized simultaneously and causing a short circuit some
preventive methods are employed , these are called interlocking methods
PUSH BUTTON INTERLOCKING

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Through KM1 the motor is fed with three phase supply for forward rotation whereas
through KM2 is fed for reverse direction of rotation.
KM1 and KM2 auxiliary contacts are called hold-on contact and are responsible for holding the
line. When forward button SB2 is pressed, NO contact closes and KM 2 coil is energized through
NC of KM1. It remain ON even when SB2 is released since NO content of contactor KM1 is now
closed.
When reverse button SB3 is pressed, NO contact closes and KM1 coil is energized through NC
of KM2. It remain ON even when SB 3 is released since NO content of contactor KM 2 is now
closed.

AUIXILARY CONTACT INTERLOCKING

In this method , interlocking is done by providing normal closed auxiliary contact of
forward contactor in series with the coil of the reverse contactor and vice versa.

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When forward button is pressed contactor coil A get energized and provides three phase
supply to the motor the forward operation hold on contact when pressure of button is released
N/B when it is energized its NC contact which has been connected in series with the
contactor coil B remains open . therefore when the motor is rotating in forward direction it
will not be possible to energize contactor B by pressing the reverse push button R similarly
it’s not possible when B is energized to energize A also .

SPEED CONTROL METHODS FOR THREE PHASE MOTORS

1] Pole changing
2] Electronic system of controlling

POLE CHANGING
Selecting a multiple wound machine [one with many sets of pole from the fact that:
N= f/p Where N= speed
F= frequency
P=pain of poles
Or varying the voltage supply to the stator winding

ELECTRONIC SYSTEM OF CONTROL

Speed control of 3phase induction motor can be achieved through:
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1] Stator voltage, variable voltage constant- frequency control.

2] Variable voltage variable - frequency control.
3] Variable current variable frequency control
4] Regulation of slip power.
STATOR VOLTAGE CONTROL

By using a Thyristor a.c controller circuit, constant frequency variable voltage supply can be
generated.
DRAWING

By changing the applied voltage air gap that can be changed so as also the slip, and motor
speed can be also altered Thyristor controller is used, where two SCR are connected in
antiparallel per phase. This is a costly arrangement since firing circuit is very complicated.

VARIABLE VOLTAGE VARIABLE FREQUENCY CONTROL

DRAWING

A.C rectified to d.c thus filtered to minimize ripple content. It is then converted to control
pulses by means of a voltage to the frequency converter which is then fed to the inverter
bridge for producing the variable voltage variable frequency output . The output is fed to the
induction motor for controlling its speed. Phase control circuit controls the firing angle of
rectifier bridge.

VARIABLE CURRENT VARIABLE FREQUENCY CONTROL

A phase controlled rectifier produces variable A.C voltage which is converted to a current
source by connecting a large inductor in series . A diode rectified followed by a D.C chopper
can also be used as a voltage source.

Drawing

ADVANTAGES

I. Control circuit smaller and more reliable.

II. the power circuit is ragged and reliable
III. Any fault on the slide causes slots rose of fault current which can be cleared by
converter slid control
IV. Less number of components in inverter circuit and less commutation loss
V. Regeneration process is simple and no additional components required.

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DISADVANTAGES

1) The inverter is somewhat bulky and expensive value to the large size of the
inductance and commutater capacitor
2) The response of the drive is somewhere slagging
3) The frequency range of the inverter is low it cannot operate under no load
condition as some minimum load current is required to commutate the
inverter satisfactory.
SLIP POWER CONTROL
With voltage and frequency fixed speed of induction motor can be renewed by injection a
conductor e. m.f. into the rotor circuit of the motor this method is used for a wound rotor
induction motor, rectified by a diode and is then pumped back to the A.C line through a line
commutated inverter .

Drawing

The torque pulsation and additional heating must be considered while designing the drive
system

DISADVATAGES

- Regeneration and speed reversal are not possible

- Draw back very poor p.f.
- Only use in large H.P pump and blower type application where limited range of
speed control is required .
SPEED CONTROL OF SYNCHRONOUS MOTOR
Can be controlled by:
- Using current –fed dc link
- Using cycloconvertor
SPEED CONTROL BY CURRENT -FED D.C LINK
Typical consist of three converters two of which are connected between the 3-phase
source and synchronous motor and third convertor [ bridge rectifier] supplies D.C
field excitation for rotor
Drawing

Connector 1[C1] act as a controlled rectified and feeds d.c power to convertor 2[ c.2]

Convertor because as a naturally commutated invertor whose A.C voltage and frequency
are established by the motor .

SPEED CONTROL BY CYCLOCONVERTER

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Consists of 3 cycloconvertor connected to the three terminals of the synchronous motor and
one controlled rectifier for supplying field exciting current to the rotor each cycloconvertor
is composed of two 3-phase bridges.

And supplies a single phase output with a frequency of 50Hz, the cycloconvertor output
frequency can be varied from 0 to 10 HZ. This can vary the speed of motor from 0 to 1 r.p.m.

DIGITAL CONTROL OF ELECTRIC MOTORS

Micro computer can be used to control the speed encoder and Analogue / digital [A/D]
convertor [speed [I/p] module]

drawing

THE PROCESS OF DESIGNING CONTROL PANEL FOR MOTORS

Control panels come in many different shapes and sizes. Standards other than the NEC also
apply to industrial control panel and NEPA79, Electrical standards for industrious machinery
there is applicable standard for design, installation testing and on maintenance. Control panel
is a cabinet which contain electrical components to control the motor and equipment.

AUTOMATIC LIFT SYSTEM

The elevator as a control system has a number of components. These can be divided into the
following
1. Inputs
2. Controller
3. Input which include :
4. Sensor
5. Buttons
6. Key control
7. System control
CABLES
Causes used for the interconnection , two types of cables are used , power cable [ which
are used to connect the motor to panel components and panel to maintain to main
supply .
2] control cables [ which are used to connect to control circuits
BUS BAR
Incoming supply is connected to two bar and distributed from bus bar, it is normally
made of aluminum.
MCB [MINIATURE CIRCUIT BREAKER]
MCB is protecting device , it is used before the feed , this should be selected according
to the capacity of the feeder .
MCCB [ MOULD CASE CIRCUIT BREAKERS]
In most of the cases the MCCB used as an incoming for higher capacity feeders for
better protection
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ELCB [EARTH LEAKAGE CIRCUIT BREAKER]

THE ELCB is also known as RCCB. The device used for the protection against the earth
leakage current and residual current . It should be fixed before the incomer

INCOME
The basic supply will connect to this income it is also called SFU [ switch fuse unit ] it
contact one handle with the fuse unit ], once it is turned on supply will pass to the next
stage through fuse any major fault occurs inside panel board it will turn and it isolate
supply .
SELECTOR SWITCH
Is used for ON/ OFF purposes and for selecting the mode of operation like auto manual.
starter are used for starting the motors safely mainly two types of starters are there .
DOL starter and star to delta, DOL stator is enough for the motor with power less than 10hp.
OVER LOAD RELAY

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Industrial Machines And Control Certificate Module II (CEEP2)
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Is the protector of motor from the over load it senses the load current and trips if it
exceed the limit , current limit has to be set manually it should be 80% of the full load
current .
TIMER
Operation of timer is similar to relay but a delay is there for actuation , we can set the
time delay mankind according to our requirements , it is very much essential for star
to delta conversion .

CONTACTOR
Contactor is an essential components in the control panel. it actuates when the signal
from the controller [ PLC Relay logic ] comes . it is similar to relay it is costlier than
relay , it is used for a higher load .
When designing the control panel, the front panel is mainly for control circuit.
Quality of the curing methods used in an industrial control panel an vary quite widely ,
the goal is to produce a panel that is logically arranged and easy to maintain for the
life of control panel .
PANEL LAYOUT CONSIDERATIONS
Optimize space
Place PLC I/0 racks in the lay created by the wiring duct to allow room for the high
density of wires going to them from the duct . Don’t leave space where there is no wiring
typically the top of the duct 1/0 rack. Place similar size devices in their own bay where
possible considered the routing of all the wires and the various voltage will be kept
separated SPACING BETWEEN wined device and wireless or other obstructions :
2’’minimum: 21/2-3 preferred for 120 VAC and lessos 4’’ for 480 Volts [ enough to insert
a closed fish between the device and the wire way another device or obstruction .
Keep the power components separate from the signal level components so that
maintenance and other engineers can work on the equipment without hazards being
present . how
1. Run as much as possible on 24 vcd. This wound include the plc.’s and most other
panel devices A safety panel would then house only there school and arc float
safe electrical components .
2. Power supply could be placed in a separate enclosure include in the main [ low
voltage ] panel and put group together and protected separately so that can be real
with then a tool when control panel door is opened .
3. Motor control running at anything over 50 volts should be contained in a separate
enclosure . try removing the motor controls away from the power device where
possible . this includes putting the HIM [key ][variable speed device ] for Example
on the out of the control panel , so that des not have to be opened .

AUTOMATIC – CONTROLLED ELEVATOR

RELAY- CONTROLL
Uses electromechanical system to control the speed position and door operation of an
elevator . they are gradually replaced by microprocessor control system which are
standard in the industry today, when designing bear in mind the pre-wired system
components
Shaft wire

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Industrial Machines And Control Certificate Module II (CEEP2)
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flexible wire
shaft device
car box
push buttons series SL
floor push button [ L.O.P]
Car push button [C.O.P]
Dark vision
TM37 Push buttons
Oval polycarbonate push button with coloured metal ring or chromed of 37 mm
diameter with numbers in relief and in accordance to EN 81.70/l E.D 24 vcc lighting
TM 40 push buttons
Car display SIL911, synoptic with all the car signals integrated
Alarm signals
Emergency lighting
Floor number ascent / descent arrow and next destination arrows , out of service
signal / surcharge signal firemen manource signal floor arrival signal floor arrival
signal .
Floor display
Electronic board to power hydraulic control panel in emergency with possibility to
reqen doors at 48 Vdc/ battery charge 12v 7AH + emergency light.
Electronic board to report power hydraulic / rope control panel in emergency with
possibility to re open any type of design

CONFIGURATION OF PROGRAMMABLE LOGIC CONTROLLRS

1] Input
2] controller
All PLC’s have four major parts powder supply processor input module and output
modules .
Drawing

Input device seem as push button switches are wired directly to the input module and
any other control devices motor starter or solenoids are connected directly to the output
module .
The program in the PLC [controller ] will determine which switch will control which
output thus physical electrical wiring needs only to connect one time during the
installation process and the control circuit can be changed unlimited times through
simple changes to the ladder logic programmed .
BASIC COMMAND FOR PROGRAMMING

i. INPUT ADDRESS
ii. Out put address
iii. Internal auxiliary relay
iv. Timer

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Industrial Machines And Control Certificate Module II (CEEP2)
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v. Counter
vi. Interruption free relay
vii. Shift register
viii. Out put relay
ix. Hold relay .
ADDRESSES FOR INPUTS AND OUTPUT FPR THE MILIROLOGIX
1000
The processor must keep track of each input and output an address or
number .
PLC has device its own numbering and addressing scheme which
generally fall into one of two categories , sequentially numbering each
input and output modules in the rack

INPUT OUTPUT
I0 00
I1 01
I2 02
I3 03
I4
011
1 19

Allen Bradley one of the most popular brands uses two different addressing system . in
its medium sized PLC’S [SLC 500 and PLCS] the address for an input or output uses
numbers that indicate the location of the input or output module in the rack and its uses
a safeguard numbering system for address in its small sized micro logic 1000lcs
N/B Each I/0 point addresses in memory are assigned to memory the addresses in a
memory block is called a meory map.

INDUSTRIAL APPLICATION THAT USES PLC

LADDER LOGIC FR THE HEAT TREATING SECTION OF THE
CARBON BRUSH- MANUFUCTURING SYSTEM .

DRAWING

INDUSTRIAL MACHINES CONTROL AND PROTECTION

- MOTOR MOUNTING
- CONTROL PANNEL [ NOTES IN OUTPUT]
- INSTRUMENTATION

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Industrial Machines And Control Certificate Module II (CEEP2)
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INSTALLATION AND MOTOR MOUNTING OF MACHINES

For safe efficient working , electrical machine must be firmly mounted and
currently installed and connected to the supply .
There are three factors which need to be considered
- Mounting or fixing the motor in position.
- Coupling the motor to the load it has to drive
- Connecting the motor to the electrical supply
- MOUNTING
- Depends on the nature of surface which must support and hold the motor in a firm
position if the floor is as thick layer of concrete the motor may be directly bolted
to it or the concrete the motor may be directly bolted to it or the concrete may be
built up to a raw / bolt or rag bolts . if the motor is to be mounted on a wooden
board floor , the weight must be spread over several joists , the boards may also
require strengthening with extra wooded or steel joints at right angles to the
exciting joints .
- drwaing

GEER TRANSMISSION

When the motor and machine have to be mounted closer on each other and A relating
larger will be required reduction drives a multi-gear train or gear box will be required .
N/B with belt drives the speed of motor and machine pulley are inversely proportional to
their diameter the larger the diameter the lower the speed . with the chain and gear drives
the speed of the toothed wheels are inversely proportional to the number of teeth . the small
– toothed wheels are referred to as pinions , the larger ones as spur wheels .

On the driven machine requires a high starting torque . it is necessary for the motor to
start off –load and then take up the drive as it gather speed . this is achieved by special
designed couplings .

FLUID COUPLING

The two haves of the coupling have specially shaped blades which are not connected to
each other i.e. The motor and machine are not coupled in the stationary position . those
blades are not coupled in the oil and as the motor shaft begins to revolve , the half –
coupling on the motor shaft scopes the oil and flings it to start rotating slowly after a
while there will both run at full speed this can be used also to reduce the high starting
current of motors with required expensive types of electrical starters .

Eddy current

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Industrial Machines And Control Certificate Module II (CEEP2)
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Uses electromagnet force A d.c current is connected to its the winging in the coupling the
motor and drive machine becomes magnetically connected .

MOTOR FINAL CIRCUIT EQUIPMENT LAYOUT

DRAWING

MOTOR CONNECTION TO SUPPLY

System wiring from motor to supply depends on the site conditions . A flexible
connection to the terminal box is necessary to allow motor movement in alighting and belt
tensioning . A separate protection conduction is fixed on the flexible conductor .

Where MICC cables are used , a loop is made near the terminal box .

SAFE USE AND PROTECTION OF MOTORS

I.E.E. Regulation

Every motor must be provided with the means to stop and start the stop device to be within
easy reach of the operator

Provision must be made to prevent unexpected restart after stopping , owing to drop in
voltage , or failure of supply both are dangerous . one device could serve a group of motors
i.e. if several small motors are fed from a distribution board then a no-volt coil release
fitted in the supply to that board would be sufficient additional equipment to lock the motor
from supply if the motor is far from control equipment .

Every motor over 0.37kw must have means of protection against excess current.

Cables supplying the motor shall be rated at the full load current taken.

MACHINE SHOP INSTALLATION

DRAWING

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Industrial Machines And Control Certificate Module II (CEEP2)
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N/B means of complying with .I.E.E. Regulation for a group of small motors in a machine
shop.

Drawing

N/B when excess current flows its movement is delayed by the suction of oil on the plunger
in the dashboard. The delay time can be varied by different sized escape holes in the plunger .
this is mainly used on motor switching gears to prevent tripping operation during the start
period .

Note - for frequent stop starting the cables may have to be heavier because of heavier
starting current

- The motor excess current device operation is suitable for starting currents. Generally
all 3-phase motor installation require a separate sub- circuit from distribution fuse
board and suitable protection against excess current [overloads] and un expected
restart [ no volt release] isolation should be provided by the motor control gear.
- All terminals on three -phase supplies must be enclosed in earthed metal or in all-
insulated enclosures.

MACHINE CHECKS
Varies instruments are required to personal checks on machine either on operational
or standing . they include insulation tester continuity tester ductor tester feeler
gauge , spring balance, straight edges and string lines .

INSTRUMENTS FOR SUPPLY –OFF CHECKS

INSULATION TESTER
Also referred to as megger . its an instrument that produces a.c voltage of 500 and is
sufficient to taste machine operating up to 650v. When testing ensure that no false
values are obtain if dealing with 3phase separate the connection points.
Minimum insulation value should be 1MΩ if machine is damp then dry up.

CONTINOUS TESTING
Checking ohmic value of winding carefully so that no false low value are obtained
if there are other connections e.g. ON controls that have low values .

DUCTOR TESTER

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Industrial Machines And Control Certificate Module II (CEEP2)
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Instrument for measuring very small resistance values that are not practical to read an
continuity tester e.g. 0.01Ω etc. the ductor circulate heavy current and measure
millivolt [mv] drop across resistance path, if this is not available then a heavy
current and measured R= V/ I –R
E.G. IF 60A Flows and the voltage 30mV then resistance = 0.0005Ω which is
difficult to read with an armature winding of a heavy current d.c machine copper
bars in the rotor of a squirrel cage motor or the joints and termination on bus bur
and heavy current cable installation .

VIBRATION CONSIDARATION
To avoid transmission of vibration to adjoining parts of building or other foundation
, it is necessary to provide a suitable isolation between the equipment foundation
and the adjoining structure usually a gap is maintained all around the foundation for
the equipment and is filled by sand to avoid such transmission of vibration the
foundation for the equipment should not be allowed to serve as a support for other
structures.
drawing

METHODS FOR INSTALLATION OF WIRING FOR TWO OR MORE MOTOR

When wiring is to be done for electric motors the following points should be followed
keeping in view the degree of protection necessary and desired economy.

-A separate circuit to be done for electric motors from fuse distribution board , this method
is generally adopted for a group of motors of small sizes .

-A separate circuit may be run to each motor from a distribution board . the fuses are to be
used in each brach circuit of ample capacity .

The frame of each motor shall be earthed by two separate and distinct connection
through each electrodes the each earth connection should be visible for periodic
inspection .

ARRANGMENT OF WIRRING CIRCUIT FOR MOTORS

DRAWING

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Industrial Machines And Control Certificate Module II (CEEP2)
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A= Supply company’s mattering panel

B= iron clad main switch near motor

C= power panel

D = triple pole iron –clad switch near motor

E= motor starter fitted with over current and no- volt material device

F= motor

G= danger notice plate

H =all cables be steel arm art

J= Card with instruments for resusciting persons suffering from electric shock

K= earth metallic tubing protection cables from the starter motor .

EP= Earthing

Dotted line shows earth connection .

GENERAL ARRANGEMENT OF WIRRING FOR THE MOTOR WITH REMOTE

CONTROL ARRANGMENT

DRAWING

SOLDERING CABLES INTO SOCKETS

All the cables must be soldering into the socket which are provided on the motor terminals
then terminals should be well tightened down, the care of cables not to cross or make
contact with each other .

TERMINAL MAKING
The terminal making are as specified in 15:325 before connecting the motor supply please
refer to the connection diagram carefully and follow the instruments special instruments if
arm will be given separately . to reverse the direction of rotation interchange any two of the
line leads for three phase motors .
Double earth for 3phase machine and equipment
How it is done?
It help in case one earth is out of the other, the other one will do the work. Two earthings
are done at a distance of about 5 meter , and t for The other earth wires should be fixed with
the help of thimbles [ plugs ] of proper sizes with different places . the two wires should not
touch each other .
TESTING OF EARTH CONTINUITY

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Industrial Machines And Control Certificate Module II (CEEP2)
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Insulation resistance is measured between conductor and earth . it is of the order of several
tens thousands mea ohims or infinity for the healthy insulation . it is measured by means of
megger [ mega- diameter] .
N/B see differences b/n earth continuity and insulation resistance for insulation resistance ,
resistance is almost infinity white for earth continuity it is zero.
MEASUREMENT OF INSTALLATION RESISTANCE BETWEEN CONDUCTORS
Insulator should be sufficient enough to avoid any possible leakage of current , the leakage
of the current should not exceed one/ five thousand part or 0.02% of full load current test is
conducted on whole installation on main switch .
Before performing insulation resistance test between conductor the position of main switch
fuses and switch should be as under :
- Main switch in off position with fuse nt.
- All switches in or position
- All lamps and other applicants should be removed .
- The fuses beyond the main shift should be in position
Drawing

INSULATION RESISTANCE TEST BETWEEN INSULATION AND EARTH

PROCEDURE

a) Switch are main switch [ OFF]

b) All switches be on
c) All fuses beyond main switch i.e in position
d) Lamps and other equipment’s be in their position
e) Connect phase and neutral terminals together and connect them to lime terminals
of the megger . the earth terminals of the megger is connected to earth continuity
conductor .
Turn the handle of tester at high speed . the value indicate by the dial indicate values
of insulation resistance value should not be less than 0.5 M r
CONTROL PANEL
Types of control panel :
1) A master control des and associated instrument panel
2) Transmission line control panel
3) General service control panels
4) Electrical auxillary control panel
5) Instrument panels
6) Synchronizing panels
7) Automatic voltage regular panels
8) Automatic voltage regulator panels
9) Carrier communication panel

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Industrial Machines And Control Certificate Module II (CEEP2)
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(a) RELAY PANNEL - relays are generally mounted on a separate panel , type and
number of relays depends on requirements .
(b) INSTRUMENTAL PANNEL - Indicating ammeter voltmeters energy meters their
selection switches recording instruments if any fitted on instrument panel .
(c) SYNCHRONOUS PANEL- The panel for synchonising can be converted arranged
on the upper portion of the cubicle , the indicating instrument show ‘’incoming
volts ‘’ ‘ bus bar volts and slow or faster .
(d) CUBICLE PANNEL : The cubicle are arranged in a line side by side , sometimes
the relay cubicles with corridor is between the corridor is roofed and through out
are provided for wiring which run between the controller and relay panels.
(e) Carrier communication panel – carrier communication panel is connected to the
power line through coupling capacitor communication can be carried out between
the station by carrier channels D.C supply for protective relating is obtained from
battery system,
(f) Automatic voltage regulating the voltage automatically
(g) Process control panel – it is used for controlling different processes .
PLANNING FOR CONTROL ROOMS
There are no hard and test rules regarding the located layout of control rooms . it is located
at one end of the shape it should be near the management office and good instrument test
room , there should be good communication between the control room and management
office it should be away from noise and disturbance .
THE LAYOUT OF CONTROL ROOM
A layout depends on the size of the substance operating requirements and type of
installation it should be design to amble to routine operation equally spaced and separate area
should be available for movement of personnel ,
If the substance is two large it will have a large number of protective relay panels control
panels and mattering panels , it is preferred to have separate panels for the following .

- Relay panels
- Metering panels
- Control panels

Drawing

The diagram of main connection are given on the front of the panel , indicating
position of the circuit breaker an isolator . control room for generate and main transmit
or are generally brought on a separate control main transistor . are generally in front
of main control board separate control desk located centrally in front of main
control desks are provided for prime –moves and boilers , in case of medium size
installation panel can be width can be increased to accommodate relay and other
equipment incase of complex protective schemes a separate relay panel .

CONSTRUCTION OF CONTROL PANNEL

Construction features vary with the manufacture and application .however , a general
pattern can be described , the control and relay boards are built of self contained

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Industrial Machines And Control Certificate Module II (CEEP2)
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sheet steel cubicles , these cubicles are assembled on common channel iron base
plates according to the needs
The cubicles are fabricated as follows : the angles iron or channel iron are cut
according to drawings . the pieces are wedged to form the frame sheets are cut on
shearing machine to require sizes

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Industrial Machines And Control Certificate Module II (CEEP2)