E-HAND

ELECTRICAL HAND BOOKTROUBLE SHOOTING

CABLE-SIZE & CB CURRENT RATING

For lighting points use 1.5mm2 PVC Cable.

Up to 15A - 2.5 mm2 Up to 175A - 95 mm2

Up to 20A - 4 mm2 Up to 200A - 120 mm2

Up to 30A - 6 mm2 Up to 225A - 120 mm2

Up to 40A - 10 mm2 Up to 250A - 150 mm2

Up to 50A - 16 mm2 Up to 300A - 185 mm2

Up to 60A - 25 mm2 Up to 350A - 185 mm2

Up to 75A - 35 mm2 Up to 400A - 240 mm2

Up to 100A - 50 mm2 Up to 500A - 300 mm2

Up to 120A - 70 mm2 Up to 630A - 400 mm2

Up to 150A - 95 mm2 Up to 750A - 500 mm2

Up to 1000A - 630 mm2

300 A and above should be EF/OC that means earth fault and overcurrent type relay to use.

200 A and under should be ZCT and ELR Zero sequence Current Transformer and Earth Leakage Relay to use.

Main DB Cable Type are as follows:

For inside the building PVC/PVC or XLPE/PVC type.

For Under Ground PVC/SWA/PVC type.

Sub-Main DB cable type should be PVC only.

From 3.3KV up to 22KV should use PVC/SWA/PVC or XLPE/DSTA/PVC type.

ECC and N choice.

1.5 mm2 to 16 mm2 Phase cables should use N-full size and E-half size

25 mm2 and above should use N-half size and E-half size.

Maximum Earth Cable size is 70 mm2

CB rating and maximum interrupt current capacity are as follows

CB Rating for Normal Maximum Interrupt Current Cap.

800A - 1250A 50KA

175A - 630A 35KA

0 - 150A 25KA

0 - 100A 10KA

0 - 100A 22KA

2500A 31MVA for 3 Sec

400A 36KA

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150A 25KA

60A, 63A MCB 10KA

20A MCB 5KA

MAXIMUM DEMAND CALCULATION ACCORDING TO SAA WIRING RULES AS 3000

AS 3000-1991AUSTRALIA STANDARD SAA WIRING RULES

Table 2.3MAXIMUM DEMAND-SINGLE AND MULTIPLE

DOMESTIC INSTALLATION1 2 3 4 5

Block of living unitLoad Group Single domestic

installation or individual living unit per phase

2 to 5 living unit per phase

6 to 20 living units per phase

21 or more living units per phase

A Lighting (i) Except as in (ii) and load group H below

3A for 1 to 20 points + 2A for each additional 20 points or part thereof

6A 5A+0.25A per living unit

0.5A per living unit

(ii) Outdoor lighting exceeding a total of 1000W

75% connected load No assessment for the purpose of maximum demand.

B (i) GPOs and socket-outlets not exceeding 10A. Permanently connected equipment not exceeding 10A and not included in other load groups.

10A for 1 to 20 points + 5A for each additional 20 points or part thereof

10A+5A per living unit

15A+3.75A per living unit


(ii) Where the installation includes one or more 15A socket-outlets other than socket outlets provided to supply equipment set out in groups C,D,E,F,G and L

10A 10A 10A 10A

(iii) Where the installation includes one more 20A socket-outlets provided to supply equipment set out in groups C,D,E,F,G and L

15A 15A 15A 15A

C Ranges, cooking, appliances, laundry equipment or socket-outlets rated at more than 10A for the connection thereof

50% connected load 15A 2.8A per living unit

2.8A per living unit

D Fixed spaced heating or air conditioning equipment, saunas or socket-outlets rated at more than 10A for the connection thereof

75% connected load 75% connected load

75% connected load

75% connected load

E Instantaneous water heaters 33.3% connected load 6A per living unit

6A per living unit


F Storage water heaters(i) controlled load

Where the full load current is less than the figure obtained under the other appropriate load groups, no assessment for the purpose of maximum demand. see footnotes

(ii) other types Full-load current 6A per living unit

6A per living unit


G Spa and swimming pool heaters

75% of the largest spa, plus 75% of the largest swimming pool, plus 25% of remainder.

LOADING NOT ASSOCIATED WITH INDIVIDUAL UNITS-CONNECTED TO EACH PHASE (PUBLIC LIGHTING, COMMUNITY LAUNDRY LOADINGS, LIFTS, MOTORS, ETC.)H Communal lighting Not applicable Full connected

loadFull connected load

Full connected load

I GPOs and socket-outlets not included in-groups J and M below.

Not applicable 2A per point 2A per point 1A per point

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Permanently connected equipment not exceeding 10A

J Appliances rated at more than 10A and socket-outlets for the connection thereof-(i) Clothes dryers, water heaters, self heating washing machines, wash boilers

Not applicable 50%connected load

50%connected load

50%connected load

(ii) Fixed spaces heating , air conditioning equipment, saunas

Not applicable 75%connected load

75%connected load

75%connected load

(iii) Spa and swimming pool heaters

Not applicable 75% of the largest spa plus 75% of the largest swimming pool, plus 25% of the remainder

K Lifts In accordance with Clause 2.6.3 Table 2.4

No assessment for purpose of calculation of maximum demand. In accordance with Clause 2.6.3, Table 2.4, determination of size of submains.

L Motors In accordance with Clause 2.6.3 Table 2.4 column 2

In accordance with Clause 2.6.3, Table 2.4, column 2

M Appliances, including socket-outlets other than those set out in group A to L above. e.g. pottery kin, welding machines, radio transmitters, X-ray equipment and the like

Connected Load 5A or less: No assessment for purpose of maximum demand.

Connected load 10A or less. No assessment for purpose of maximum demand.

Over 5A by local authority permission

Connected load over 10A. by assessment of the inspecting Authority

Footnotes to table 2.3a. For multiphase connections, divide the number of living units by the number of supply phases, e.g. 16units on a three phase supply, 16/3 = 6 units on the heaviest loaded phase (Column 4)b. Where only a portion of the number of units in a multiple installation is equipped with permanently connected or fixed appliances, such as electric cooking ranges or space heating equipment, the number of appliances in each category is divided over the number of phases, and the maximum demand determined as shown in Example 3 of Appendix G.c. Lighting track systems shall be regarded as 2 points per meter of track.d. This load group is not applicable to socket-outlets installed in Communal area but not connected for the individual living units. Su /ch socket outlets should be included in load group B.e. For purpose of determining maximum demand, multiple combination socket-outlets shall be regarded as the same number of points as the number of integral socket-outlets in combination.f. Where an installation contains 15A or 20A socket outlets covered by load group B(ii) or B(iii), the base loading of load group B is increased by 10A or 15A respectively; if both 15A and 20A socket-outlets are installed. The increased is 15A.g. Where and installation includes an air-conditioning system for use in hot weather and a heating system for use in cool weather, only that system which has the greater load shall be taken into account.h. Flood lighting, swimming pool lighting and tennis court lighting and likei. Instananeous water heaters including 'quick recovery' heaters having element ratings greater than 100W/Lj. Storage type water heaters, including 'quick recovery' heaters not referred to in footnotes.k. Controlled loading is taken to include only loading to which supply is controlled by the supply Authority so that it is available only for limited period of time. Where the full load current of the controlled load exceeds the maximum demand calculated using all appropriate items of this Table, the full load current of the controlled load together with group A(ii) and group H shall be taken as the maximum demand for the installation.l. In the calculation of the connected load, the following rating shall be assigned to lighting.

(i) Incandescent lamps 60W or the actual wattage of the lamp to be installed, whichever is greater, except that if the design of the lumanrie associated with the lampholder permits only lamps of less than 60W to be inserted in any lampholder, the connected load of that lampholder shall be the wattage of the highest rated lamp which may be accommodated. For multi-lamp luminaries, the load for each lampholder shall be assessed on the above basis.

(ii) Fluorescent and Full connected load, i.e. the actual current consumed by the lighting other discharge arrangement having regard to auxiliary equipment such as ballast and

lamp capacitors.

(iii) Lighting Tracks 0.5A/m per phase of track or the actual connected load, whichever is greater.

m. A socket outlet installed more than 2.3 m above a floor for the connection an appliance rated at not

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more than 100W or a lumanrie may be included as a lighting point in load group A(i). An appliance having not exceeding 100W, which is permanently connected or connected by means of a socket outlet installed more than 2.3m above a floor, may be considered as a lighting point.

n. Each item of permanently connected equipment not exceeding 10A may be included in load group B(i) as an additional point.

1 2 3Load group Residential Institutions,

hotels, boarding houses, hospital, accommodation houses, motels

Factories, shops, stores, offices, business premises

A. Lighting other than in load group F 75% connected load Full connected loadB.(i) GPOs and socket outlets not exceeding

10A other than those in B(ii)1000W for first socket outlet plus 400W for each additional outlet.

1000W for first socket outlet plus 750W for each additional outlet

(ii) GPOs and socket outlets not exceeding 10A in building or potions of buildings provided with permanently installed heating or cooling equipment or both.

1000W for first socket outlet plus 100W for each additional outlet.

1000W for first socket outlet plus 100W for each additional outlet.

(iii) Socket outlets exceeding 10A Full current rating of highest rated socket outlets plus 50% of full current rating of remainder

Full current rating of highest rated socket outlets plus 75% of full load of remainder

C. Appliances for cooking, heating and cooling, including instantaneous water heaters, but not appliances included in group D & J.

Full current rating of highest rated appliance plus 50% of full current rating of remainder

Full current rating of highest rated appliance plus 75% of full current rating of remainder

D. Motor other than in E and F below Full load of highest rated motor plus 50% of full load of remainder

Full load of highest rated motor plus 75% of second highest rated motor plus 50% of full load of remainder

E. Lifts (i) Largest lift motor - 125% full load(ii) Next largest lift motor - 75% full load(iii) Remaining motors - 50% full loadFor the purpose of this load group, the full load current of a lift motor shall mean the current taken from the supply when lifting maximum rated load at maximum rated speed.

F. Fuel dispensing units (i) Motors : First motor - full load Second motor - 50% full load Additional motor - 25% of full load(ii) Lighting - full connected load

G. Swimming pools, spas, saunas, thermal storage heaters including water heaters, space heaters, and similar arrangements

(i) Continuous elements - full load in all cases(ii) Controlled elements (including controlled element which may be connected to the supply at other than controlled times by means of a change over switch or load controlled systems): 66% of full load where the demand of the rest of the installation as calculated is not less than that of the controlled element.Full load in all other cases

H. Welding machines In accordance with clause 2.6.4, takings into account power factor correction.

J. X-ray equipment 50% of the full load of the largest X-ray unit, additional units being ignored.

K. Other equipment not covered by load group above

By assessment of the inspecting Authority

a. In the calculation of connected load, the following ratings shall be assigned to lighting:(i) Incandescent lamp - 60W or the actual wattage of the lamp to be installed, whichever is the greater, except that if the design of the luminaries associated with the lampholder permits only lamps of less than 60W to be inserted in any lamp holder, the connected load of lamp holder shall be the wattage of the highest rated lamp which may be accommodated. For multi - lamp luminaries, the load for each lampholder shall be assessed on the above basis.(ii) Fluorescent lamp - Full connected load, i.e. the actual current consumed by the lighting arrangement having regard to auxiliary equipment such as ballast and capacitors.

b. Load group B(ii) applies to building or portion of building incorporating permanently installed heating and/or cooling equipment specifically provided to render unnessary to the use of general-purpose outlets for portable electric space heating or cooling appliances. Whether heating or cooling or both is deemed necessary to avoid the use of portable heating or cooling equipment will depend on the location and climate involved.

c. Controlled loading is taken to include only loading to which supply is available for a limited Period of time.

d. A socket outlet installed more than 2.3m above a floor for the connection of an appliance rated at

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not more than 100W or a luminary may be included as a lighting point in load group A. An appliance having a rating not exceeding 100W, which is permanently connected, connected by means of a socket outlet installed more than 2.3 m above a floor may be considered as a lighting point.

e. See clause 2.5 9(ii) , Clause 2.8.2 and clause 2.9.3 for where the maximum demand for consumers main and submains, and final subcircuits respectively may be determined by limitation.

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TRANSFORMER TROUBLE SHOOTING

sno. Parts Trouble Possible1 Insulation oil Overheat Lower than oil level.

Block oily dirt in cooling lines. Overload.

Weak in di-electric strength

Water moisture, vapor, dirt include in oil flowing, because breathing equipment can't clean them.

Bad in Gaskets as wears and tears. Acid and oily dirt

come out Overheating. Oil viscosity not corrects.

2 Breather Not absorb water moisture

Something damages or not corrects in chemical.

3 Windings Overheating Overload Lower in oil level. So many oily dirt in bottom of oil tank. Oily dirt blocks in cooling pipelines.

Noisy Losing in clamps or Bolts & nuts Weak in insulation

resistance Water includes in oil or acid includes in oil. Touch in air. Not enclosed with air.

4 Core Overheating Noisy

Core insulation damage. Loosing in bolts and nuts.

5 Insulation Hard & easy to crack

Overheating Very long in life or life in finish.

6 Enclosure(Air part)

Rust Acid in oil

7 Thermometer Not correct indication

Not correct in Connection. Some problem in Bulb or Tube.

Remark: There are 75-degree centigrades to 80-degree centigrade in oil temperature. It must be filled in oil level that is pre-mark. It must not be leakage in oil tube, drain cock, gasket. If there are water in oil, the color will be mud color. But should not assume as always.

Crack test: The method which is the best way to know whether oil mix with water or not.

method: (1) close one end of capillary tube, size in 1-inch diameter.

(2) heat until red-brown color.(3) poured into sample oil which you want to know, and listen by the other end.

no water inside-sh!!water inside-explode!!

Silica Gel: It is a type of chemical which absorbs moisture or vapor. It will slowly change the violent color to pill pink color as ratio which absorbed moisture or vapor. It must be change new silica gel where the old is totally pink color.

heat treatment: When 300 degree F to 400 degree F heating to old silica gel, the color get it back original violent that is to get it out moisture or vapor.

It should be inspected in every 6-month or 1-year regularly.

TRANSFORMER MAINTAINANCE

1. External seeing inspection.2. Using instruments inspection

1.External seeing inspection

(1) Insulation oil leakage or little than marking.: Put red color float into oil indicator glass & see. If it is lower than marking, it is known as not enough oil.

(2) Blue color crystal change in color or not: Breather crystal which is blue color change to pink color means saturated in moisture or vapor, must be change or put under sun or heat supply.

(3) Porcelain & ceramic isolator crack or not

2. Using Instrument inspection(1) Winding insulation testing. : LT winding testing - short circuit to HT winding line 3 terminals.

also short circuit to LT winding lines 3 terminals. take off Earth wire Megger testing: Line to LT short terminal & Earth to Transformer body.

: HT winding testing - similarly as LT winding testing.

: Test Result: not lower than 1000 ohms/v is good

: for 230V is good in 230K-ohms or 0.23M-ohms

: for 400V is good in 0.4M-ohms

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: for 11KV is good in 11M-ohms

Insulation oil condition testing.: Get the sample oil which can get transformer bottom oil drain hole

Testing by Insulation oil tester

Wash to Sphere in instrument by oil.

After no more bubble in oil, line switch on.

Put until 11KV & slowly increase.

Wait a moment when every 5KV increase.

Nothing happen until 40KV - it is good.

If oil is not pure spark between two sphere & automatic trip.

It must be stand 1min in 40KV.

When testing 5 times- 4 times were in good, oil is good.

Some type of oil can stand 45KV to 50KV.

(Reference by U Pe Thein )

Earth testing or Ground testing.

Transformer TroubleshootingSr.no. Symptom Trouble Cause Remedy1 Temperature of oil

cooled transformer rise until serious level.

1a. Overload 1a. Poor powerfactor and overload

1a. Decrease load and powerfactor correction

1b. Not enough oil in oil tank

1b. Leak in oil tank or not enough filling

1b. Repair it, or oil fill until transformer core is under oil level

1c. Oil viscosity grade so high.

1c. Cannot transfer heat, it is so hot until windings burn and insulation damage

1c. If it was insulation damage, drain off old oil and clean it. new oil replaces it.

2 Temperature of air-cooled transformer rises until serious level.

2a. Over load 2a. Poor powerfactor and overload


2b. Not enough air volume

2b. Air circulating or air blowing very weak or block in air pipe

2b. Increase air circulating rate. or clean air pipe

3. Temperature of water-cooled transformer rises until serious level.

3a. Over load 3a. Poor powerfactor and overload


3b. Not enough water flow in pipe

3b. Something like oil dirt block in pipe

3b. Water force applied, cleaning by soap clean to oil and oil dirt, coils are under oil level.

3c. Oil dirt is stuck on the cooling pipes surface.

3c. Transformer working in so less temperature.

Transformer temp must not less than 10deg C.

3c. If oil dirt on pipes cannot remove, disassemble the cooling coils and the coolest pipes to clean by scratch method.

4. Explode sound in transformer tank.

Neighbor wire layers of HV winding are in short circuit.

Cooling coil surface of air cooled or oil cooled transformer are in small holes or leakage moisture go inside, so transformer temperature drop under 10deg.C

Test to transformer oil if cannot get standard level, check again and refill it.

Short circuit between HV winding and LV winding.

Insulation drops or damage.Switch on/off when full load condition.

Replace to damage coil.

End part connection of wire insulation

Change to damage coils and end parts'

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troubleActually that part insulation is 5 times better than inner parts.

insulation should be replaced by thicker size.

Core construction not so nice.

Sends back to manufacturer and repair it.

Transformer coils are placed in not correct position.

It will become short circuit, so repair and re fitting.

No lightning protection, so when lightning times the effect of lightning surge make it.

Repair to damage coils, replace new coils.Every transformer has lightning protection, the lightning protection are series with choke coil, reactor etc.

When storm coming, short circuit in line to line and short to transformer.

Replace damages coil and put thicker insulation to end parts of wire.

LV winding ground to core.

By lightning strike, hit line to line and insulation weakness.

Replace damages coil and put thicker insulation to end parts of wire.Send back to manufacturer and repair it

Short circuit on terminal board

Oil mixed with moisture.

Repair to terminal board and repaint by varnish. It should separate oil and moisture by filter.

Short circuit in HV or LV bushing.

Damage in bushing. Replace to bushing.

Not equal load sharing

Parallel operation to different characteristic two transformers.

It must be same characteristic transformer to parallel operation, otherwise put in reactance between two transformers.

Damage LV winding HV side in ground, when there are no ground neutral.

Open to ground and then repair to LV winding.Ground connection to LV and HV neutral.

HV side in ground and LV neutral connect to ground.

Open to ground and then repair to LV winding.Ground connection to LV and HV neutral

5. Different temperature in transformer which has star neutral ground

Ground in a phase Insulation drop or a line to ground in transformer.

Open immediately to line otherwise short harzard in transformer, and then find out the location that ground coil and insulation put in or add in.

6. Different temperature in transformer which has primary star - secondary delta.

Ground somewhere to a primary phase.

Same symptom likes above cause.

Same manner as above.

7. Different phase voltage in a 3 phase transformer.

Ground in a phase of star-delta transformer. the other two phases are 1.732 times bigger

Insulation damage in line, ground somewhere in line, transformer insulation drop.

Take off or cut out where trouble found, and then repair to ground trouble, replace with new insulators, bushings.

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If trouble found in winding, repair as re-winding.

A transformer bucking or counter acts to other transformers.

Its polarity opposite among other, if it is not repaired one or more transformers will be burned out.

To check polarity to get correct and then change polarity of transformer which is trouble.

8. Very less voltage Wrong ratio calculated

It is not correctly connected to correct ratio tapping.

Raise up tapping numbers to get until necessary voltage.

9. Very high voltage Wrong ratio calculated

Same symptom as above

Drop down tapping numbers to get until necessary voltage

Parallel connected to transformers which were in different ratio

Change transformers until same ratios to get, if cannot adjust, replace and use to same ratio new transformers

AUTO STEP-UP TRANSFORMER DESIGN(for Domestic use in Myanmar)@Relationship in power Vs voltage and current P = V x I

Where P = Power required in Watt. V = Terminal supplied voltage (Volt) I = Current (Ampere)

@Relationship in iron core cross sectional area Vs width and breadthA = X x YWhere A = Iron Core Cross Sectional Area in sq.-inch

X = Width of the Iron Core Cross Section in inch.Y = Breadth of the Iron Core Cross Section in inch.

@Relationship between iron core c.s.a vs power outputA = SQRT(W)/5.58 OR A = 0.17 x SQRT(W)Where A = Iron Core Cross Sectional Area in sq.-inch

W = Power Out put in Watt

@Relationship for core iron quality vs turns per volt. For good quality N = 8/A Where N = turns/volt, A = CSA in sq-in For fair quality N = 10/A For bad quality N = 12/A

@General Formulae for EMFE = 4.44 BNFA x 10-8 VoltWhere E = EMF in volt

@Table for Current vs Wire SWG Gauge SelectionSWG Current Turns/inch Turns/sq-in SWG Current Turns/inch Turns/sq-in1 141.4 3.1 - 24. 0.760 42.4 17892 119.6 3.6 - 25. 0.628 46.5 20703 99.8 4.0 -- 26. 0.510 51.5 26504 84.6 4.3 - 27. 0.422 56.5 31905 70.6 4.7 - 28. 0.344 62.5 39006 58.0 5.2 - 29. 0.290 67.6 45507 48.6 5.6 - 30. 0.242 74.6 55508 40.2 6.0 - 31. 0.212 79.4 63009 32.6 6.7 44.89 32. 0.184 85.7 730010 25.8 7.6 57.76 33. 0.156 91.7 840011 21.2 8.5 72.25 34. 0.132 100 1000012 17.0 9.2 84.64 35. 0.110 109 1200013 13.2 13.8 116.64 36. 0.090 120 1450014 10.0 12.1 146.41 37. 0.072 135 1820015 8.140 13.7 176.00 38. 0.056 151 2290016 6.440 14.8 219.00 39. 0.042 175 3060017 4.920 16.9 285.61 40. 0.036 180 3560018 3.620 19.7 388.00 41. 0.030 2 4300019 2.520 23.5 550.00 42. 0.024 227 5100020 2.040 26.0 676.00 43. 0.020 256 6500021 1.608 29.2 852.00 44. 0.016 285 8100022 1.240 33.0 1089.00 45. 0.0122 322 10400023 0.904 38.3 1513.00 46. 0.0090 377 142000

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Designing Procedure for Auto Step-up Transformer in Residential use. Find the Total load in Power (Watt) Calculate to I in Ampere by Power formulae P = V x I Where V is standard terminal supply voltage. From I value in above table , find out the wire gauge size in SWG. What is your iron core size in your hand or thinking the core size by rule of thumb. Calculate iron core CSA from formulae A = X" x Y" Depends on the iron core CSA, find out the turns per volt form N=8/A, 10/A or 12/A For 220V stable standard system, 80V should be at least point of input voltage in supply (primary side in

autotransformer). So decide the turns of required voltage tapping. Also find out the turns/layer. Draw the terminal schematic drawing for auto-step-up transformer. Decide that manual, semi-auto, fully auto control system to use in control.

DRAWING SIZE & ARRANGEMENT( Referred to AutoCAD 12 for Windows, AutoCAD 13 for Windows & AutoCAD 14 )

Display Area on the PaperPaper Size Display Area in mm Scale in inch

A0 1140 x 800A1 795 x 560A2 554 x 388A3 380 x 265A4 210 x 297 11.2

Scale Printing1. Set in control panel setting range as 210 x 297mm A4 size2. Unprinting area 160 top/ bottom / left / right3. Set in print set up in ACAD4. Scale to fit 1/4 ===> 1"~4' ====> 11.2 ===> 760.1466 (or) 63' 4-19/125" 1/8 ===> 1"~8' ====> 11.2 ===> 1520.2932 3/32"==> 3"~32'====> 11.2 ===> 2027.1104 (or) 168' 11-7/64"Scale Multiply factor Arrow

SizeExt. Line

Ext. Line Original Offset

Dimension line spacing

Text height

Text Gap

Tolerance Height

1/4" 4x1.414x11.2x12 4" 6" 6" 3/8" 6" 3/32" 1"3/32" 32/3x1.414x11.2x12 1'-6" 1' 1' 6" 1' 3/32" 1"1/32" 32x1.414x11.2x12 2' 2' 2' 3/8" 2' 4" 1"3/16" 16/3x1.414x11.2x12 9" 1' 1' 49/128" 1' 3/32" 1"

ANALYZING MOTOR TROUBLE

Procedure for Analyzing Motor Trouble

1. Inspect the motor to detect mechanical trouble as broken or cracked end plates, badly bent shaft, and broken or burned leads.

2. Test the motor for bearing trouble move up and down , turn the rotor by hand, fuse burn out.

3. Whether or not the internal wires are touching the iron cores of the rotor or stator ground test using by test lamp or megger.

4. Running test to the motor - switch closed few seconds.

Fuse blow The winding may smoke The motor may rotate slowly or

noisily. It may not turn all.

Repair to damage winding procedure.Remove end plate and test to winding carefully.

1. Taking data.2. Stripping the winding.

3. Insulating the slots.4. Rewinding.5. Connecting the winding.6. Testing.7. Baking and and varnishing.

1. Taking data.

Winding data

1. Name plate data, 2. The number of poles3. The pitch of the coil ( the number of slots

that each coil spans )4. The number of turn in each coil.5. The size of the wire of each winding6. The kind of connection ( series or parallel )7. The position of each winding in relation to

other windings.8. The type of winding (whether hand, form of

skein )9. Slot insulation, both size and kind.10. Number of slots.

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Name plate data

1. Manufacturer's type and frame designation.

2. Horse power out put.3. Time rating.4. Temperature.5. RPM at full load.6. Frequency, cycles per second (Hertz)7. Number of phases.8. Voltage9. Full load amperes10. Code11. Design letter for integral HP motors

12. For motor equipped with thermal protection and for motor rated more than 1 h.p. a type number.

13. Service factor.

2. Stripping the winding

Remove the wedges. Varnish melting. Turn and wire size record.

3. Insulation the slots

Magnet wire type and insulation classes.

Slot insulation (paper).

4. Rewinding

Hand winding method. Form winding method. Skein winding method.

5. Winding Connection

Series connection or parallel connection.

Splicing and taping.

6. Testing the winding

Short Grounds Open circuit Incorrect connections.

7. Baking and Varnishing

Baking Oven at 250 Deg. F 1 hour. Dipping the varnish. Soak in the varnish 1/2-hour. Air drying varnish - fractional h.p.

motor / Class A type thermal / Heated by 1/2 voltage to winding. Exposy resin or polyester varnish

poured. Winding heated by sending

current about 5 min. All time ½ hour.

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ALTERNATORAlternator

Stationary Field & Rotating Armature Stationary Armature & Rotating Field

Small Capacity Large Capacity

Salient Pole Cylindrical PoleLarge Diameter Small Diameter

Short Axial length Long axial lengthLow Speed High Speed

ALTERNATOR TROUBLE SHOOTING & REPAIR

sr.no Fault Possible Case Repair Method1. Absolute temperature so

highOverload Release the mechanical power load in

motor, supplied by alternator.Take off the no important feeder.

Dirt or foreign particles block to air inlet & outlet or filter in force cooling air system.

Cleaning to filters.

Unbalance load in 3-phase alternator.

Re-share phase-current to get in balance.

2. Overheat in rotating winding

Overload Release the mechanical power load in motor, supplied by alternator.Take off the no important feeder.

Over excitation when very low power factor.

Power factor correction1. Capacitor fixing2. Using synchronous motor : it is better

method because it can get mechanical power and good power factor.

Something happens (fault) in prime mover therefore slow in speed & gives it over excitation.

Find out & repair that what happen to slow speed in revolution of machine.

Not enough filed winding Over winding in AC-winding , so over in DC volt.

3 Vibration & Overheat in rotating filed winding{ Carefully check in log that means check in excitation ammeter reading, if it is in suddenly abnormal means suddenly short circuit in winding}

There are short circuit turns in field winding, although it is so much rotor current , higher in lagging power factor because it's ampere-turn is less.As in experience - End windings' short circuit are happened as following factors:-Big Alternators' cylindrical rotors are many times in start/stop overheat and overcool depends upon weather in surrounding or other factorscentrifugal force

Test run in no load to make sure that it is fault happen in machine as vibration.Vibration is happened that it is not fair in magnetism.When in standstill condition nothing happen, but it is short circuit in running condition.see note(1)Field winding should be not damage to take care as following cautions:-OverheatOverloadSo many times in start/stop

4 Spark in Slip-ringOverheat in Brushes and Slip-ring

There are unbalance current sharing in brushes.1. Unequal in brush pressure2. Slip ring contain in different

type brushes or un-meshing brushes use together.

1. Equal pressure in every brush and increase if necessary.

2. Use correct brushes as manufacturer's advice. If in case use brasso to smooth

brushes surface for equal current intensity.

3. Air-film under some brushes and overcurrent flow in other un-necessary brushes.

Making small slot as length on brush's surface for blow out dirt and get it in good contact, also can get good cooling

Over contact voltage on brushes surfaces because so many dirt on it.

To omit this effect, making slot pattern like spiral grove.

5 Over temperature in negative

As current flowing direction for bronze, brass material more ware and tear effect in negative brushes than positive brushes.

To omit this effect, must be change in polarity as in time. Nothing failure in steel ring.

6 Unstable load current 6.1. Something failure in driving motor's rotor. Over slip in belt Problem in primemover's governor

6.1. To find out in external failure.

6.2. Sometime short circuit in rotating field Sometime open circuit in exciter. Damage connection in regulator rotating field.

6.2. To find out in trouble and repair it. Field AC/DC regulator fault happen

6.3. Unbalance load like Furnace or Welding set.

6.3. Should not supply by single alternator as in main.

7 No electricity in alternator

Exciter fault7.1. Problem in exciter /ac

winding7.2. Problem in exciter /dc

winding7.3. Problem in diode, voltage

regulator.7a. Open circuit in field

winding terminals or field regulator.

7a. Find out in location and repair it.

7b. Loosing in terminals or joint of regulator therefore shunt field circuit resistance so much.

7b. Find out in location and repair it

7c. More parts of filed winding become outside so those short circuit in field coil or terminals.

Other way short circuit among external winding and field winding.

7c. Inspection, checking and repair it for damage windings or terminals.

7d. Residual magnetism loses. 7d. Take off the connection and supply by battery in few or more minutes then re-connect back as origin.

7e. Reverse in field winding 7e. Re-connect backs field winding and run as over speed limit, if it require short circuit to the armature to increase excitation.

7f. Field coils or a field coil reverse connection

7f. Checking and re -connect back as corrects in pole and polarity.

7g. Slow excitation because wrong in field regulator terminals connection.

7g. Checking and re -connect back as corrects in regulator connection terminals.

7h. Commutator & contact

resistance so mush

(i) Dirty in commutator or dirty in rinse.(ii) Not enough in brush pressure

(i) Cleaning to commutator surface

(ii) Raise up to brush spring tension.

7i. After maintenance, something wrong in brush positions.

7i. Reposition in correct brush position.

7j. Failure in rotating field circuit

wrong in connection open circuit in winding not enough contact area on slip-ring

7j. Find out failure and repair it.

7k. After maintenance, wrong connection terminals in field circuit.

7k. Inspection and correctly re-connect back or re-assemble to get correct poles.

7l. Not include in more parts of excitation winding because there are short or earth fault in field system.

7l. Inspection to part of winding which is failure and repairs it.

7m. Open circuit in stator winding

7m. Using necessary testing methods to know that where is it failure? and repair it.

8 Very low voltage produce

Excitation defects8a. Very high resistance in

executor circuit.8a. Take off extra resistance by regulator

or wrong connection and poor contact to repair it.

8b. Reverse connection to field coils or coils

8b. Reconnect coils' terminals correctly.

8c. Wrong brush position 8c. Reposition it8d. After maintained, field coils

were wrongly connected as series that means originally parallel connection.

8d. Reconnect it.

8e. Short circuit in coils or a coil

8e. Repair to damage coils or coil.

8f. It is so big air gap , after maintenance that means wrongly fixed

8f. Reposition and refit back as correctly to get it correctly.

8g. Remark - Not enough field excitation otherwise it is AC excitation winding so it's taking voltage is as transformer reaction. Therefore it cannot take so much voltage.

Eacless-->i less -->less-->Ephless

8g. I=Power/Eph >> I so much >>winding burn

8h. Very less in rpm. 8h. Increase in rpm up to correct speed by major source to repair that means governor.

8i. Short circuit in revolving field winding connection reverse in connection. So much vibration.

8i. Find out the trouble and repair it. Reconnect back to get correct pole sequence

8h. Most of the windings are shorted circuit so field winding is not included

8h. Find out the trouble coil and repair it.1. Measured resistance by

Ohmmeter

2. Supply fair reduce voltage to stator ,so rotor winding got induced emf and hot in defective coil3. Also find out short circuit come out only in motor running time.

8i. When it is repaired to winding, reversibly and wrongly connected to some stator windings

8i. Checks in voltage as phase by phase and find out wrongly connected coils and reconnect back as correctly.

9 Current suddenly exceed and unstable in phase

Suddenly increase in load on alternator, so the exciter unstable then its' polarity in reverse and decrease in flux as very short time

Position to brush ahead then it gets enough increase field current and it gets enough voltage and then stable in exciter condition.Otherwise series resistance adds to field winding to get the stable in exciter condition.see. Remark 2.

10 Exciter polarity reverse Short circuit on the system so re-close shunt field switch in very short time(in second), therefore rotor induced emf is reversed with exciter shunt field.

Series field winding protect to be polarity reverse, So it should use AVR and pilot exciter, supply to main exciter and can get stability and correct polarity.

11 Unstable in alternator voltage.

11a.So much capacitive load, effect to increase voltage and unstable in self excitation and alternator.

11a.It should not supply to many capacitive loads by an alternator.

11b.Induction motor loads are suddenly increase and then decrease, so filed decrease and voltage decrease by armature reaction

11b.It can be voltage stability by necessary voltage regulator. Some alternator's rotor excitation must be increased in very short period because of its armature reactance natures.

12 Unequal load sharing in parallel operation of alternators.

There are different characteristic in alternators and exciters

It should change be excitation so watt less load changed.Adjust prime mover output and it can get useful output power.

13 Hunting in parallel operation.

13a.One or more alternator/s prime mover in defects.

13a.Discuss with prime mover manufacturer because of it is very poor synchronism and hunting.

It is only prime mover manufacturer responsibility.

13b.Unstable steam pressure or poor governor, so it is mechanical impulse in prime mover.

13a.Same as above

14 Circulating current in parallel operating alternators

Combined two star points which are not same in characteristic.

Decrease fair current by reactor fixing.Earthing in parallel operated governors, so it happens that circulating current by harmonic frequency.

15 Poor regulation in parallel operation

Unmatching regulator was wrongly installed .e.g. Current coils terminals of compound regulator were reversibly connected so that over excitation and more reactive component KVAR

AVRs connection should be as followed1. Current coil in one phase.2. Voltage coil in other two phasesIt can get voltage and powerfactor in same with one to another.

16 Suddenly voltage drop when parallel operation

One phase is out of sequence in 3 phase system

JK contactor of field exciters are series connection so it share with same field

in two generators excitation therefore take off a generator a while from synchronism. But if it correct one ,system is OK, otherwise black out.

Note 1. Short circuit by centrifugal force can be tested by DC resistance measurement. Measurement should be start from standstill to various rpm .If it is suddenly change in resistance to know as it is in short circuit. Also same way measure in pole by pole to know which is defective.

Note 2. It should be fix necessary stability plate in exciter's field magnet. That means an iron sheet, smaller csa than pole csa, is put between pole and yoke as magnetic circuit. Thickness and area of iron sheet is rule of thumb. Exciter's field switch must be close otherwise residual flux will be loss.

Note 3. Stability test : Measure short circuit full load stator current excitation. Also measure open circuit normal voltage excitation. Summation of above two is full load, zero lagging power factor load excitation for required voltage.

Note 4. Governors should be same characteristic so it can get useful load sharing.

Alternators should have same voltage regulation .Main mechanical force supply to filed regulators can get same voltage curves of exciter. It should be same voltage regulation. It should be same steps in voltage regulator.

Parallel Operation AlternatorsThe reasons for parallel operation1. It is the best efficiency in 75% to 100% load, so it can get the cost per unit amount for generation and good in load factor.2. Small machines can be matained easily that means some are running , some standby and some overhauling. If it has good

rotation program for maintenance can avoid the major damage and continuously supply.3. It is easy to upgrade the generation station to supply higher demand.Parallel operation procedure1. Correct phase sequence connection that mean correct in RYB or 123.2. Same or equal frequencies of the alternators.3. Busbar voltage and Generator paralleled voltage must be equal. It can get adjust to field excitation at pre mark speed of

rotation.4. It must know that exact time at synchronizing It can be known by synchroscope, dark lamp method, bright lamp method,

one dark two bright lamp method.

DC MOTOR TROUBLE SHOOTING & REPAIR

Sr.No. Fault Possible Case Reminds1. Motor not running 1.1 Voltage loss at motor

terminals1.1.1. Check main switch, if fuse burn out, replace new one.1.1.2. If it is not fuse blown, check starter starting resistors. It may be opened at resistance section.

1.2 Overload 1.2.1. Run motor in no load that means take off belt from motor pulley, if it is gear motor take it out and run no load. If motor run in smoothly ,change to bigger h.p. motor

1.3 Armature short-circuit or open circuit.

1.3.1. Check and see whether good contact in brush and commutator or not.1.3.2. If it is in good contact check armature coils.

1.4 Field circuit open or short.

1.4.1 Check field circuit and field coils as one by one.1.4.2 Off load and turn pulley by hand if it is not running, it may be bearing frozen, not correct position.1.4.3 Check air gap between armature and pole.

2. Motor run, but starter off many short times

2.1. No magnetic force in holding coil or very weak magnetism.

2.1.1. Check open circuit in field coil, it may be field coils terminals open or lose connection.2.1.2. Check no volt release coil working or not

2.2. Not enough torque for overload.

2.2.1. Check supply voltage ( rated or less 2.2.2. Decrease load and run to motor, it may be not correct size (small) hp.

3. Suddenly stop when motor was running.

3.1 Electricity failure 3.1.1 Check main switch.3.1.2 Check starter protection devices.

3.2 Overload 3.2.1 Check mechanical part, it may be suddenly increased load

4 Very noisy 4.1 Loose in shaft sleeve bearing

4.1.1. Check it is straight motor pulley and mechanical driven (load) part.

4.2 Over vibrating orExcessive vibration

4.2.1 Check it is balance weight on armature 4.2.2 Check loose bearing

4.3 Armature winding's wedges are loose

4.3.1 Check every coils, every slots, every wedges 4.3.2 Check binding strings which tie to coils are broken or not.

5. Over heat in commutator

5.1 Brushes are not correct position

5.1.1 Dismantle the brushes from their holder and adjust the placing.

5.2 Over pressure in brushes springs.

5.2.1 Check spring pressure to every brushes and make any adjustment

6. Armature overheat 6.1 Motor overload 6.1.1 Decrease load 6.1.2 Change to bigger capacity motor

6.2 Something blocks in armature core ventilation.

6.2.1 Check ground in armature by instruments. ( Megger, growler tester )6.2.2 Check short circuit in armature by instruments.( Megger, growler tester )

7. Overheat in field coils

7.1 Turn short in field coils

Disconnect field coils' connection Measure each coils resistance. It

must be the same value.

Low value coil's resistance means turn short.

If a little turn short must be painted insulation or varnish

If very harzard damage in coil to rewinding.

8. Motor runs very slowly

8.1 Short circuit in armature or commutator. Carbon particle stuck on commutator.

8.1.1 Check short circuit in which coil of armature.8.1.2 Also check short circuit in which commutator segment.Can test by means of megger or external glower.

8.2 Pole shoe and armature touched when it is running.

8.2.1 Take out shin iron strips which are under the poles and adjust to get correct clearance between pole shoe and armature.

8.3 Over press brushes and commutator.

8.3.1 Check it is become rough surface on commutator's face.8.3.2 Check loose in brush holder.8.3.3. Check spring pressure correct or not.

9. Sparking in brushes 9.1 Out of position in commutators

9.1.1 Check spring pressure 9.1.2 Check it is smooth surface on commutator face.9.1.3 Check brushes and brushes holders position correct or not.

9.2 Brushes are out of M.N.A or without M.N.A

9.2.1 Find out Neutral point and reposition brushes.

9.3 Overload 9.3.1 Decrease load9.3.2 Replace bigger capacity motor.

10. Overheat in bearing 10.1 Grease frozen in bearing housing

10.1 Read instruction of manufacturer and follow it.

10.2 Not enough lubrication in bearing.

10.2.1 Read instruction of manufacturer and follow it.10.2.2 Check it is correct lubricating oil or not and put in.

10.3 Over tension in belt or chain.

10.3 Decrease tension.

CONTACTOR THEORYContactor Theory1. Normal Using : Surface of the contactor roughness depends upon the ratio of interruption and closing number of times that means closing at 5 times of rated current , interruption at 2million times of rated current and so many time interruption and closing contactors.It is very little chance to compare that deformation in edge of the contactor by wear and tear.Until color of contactor change to dark blue color, it is no problem so can use continuously.

2. Closing/Interruption at Overcurrent : Surface of roughness and deformation of contactor can be come out when 2 times of rated current. Edges of the contactor spread out . It can see that silver spot on the dark blue contactor surface, but it is no need to do any maintenance.

3. Suddenly and So many times open and closing at Inrush Current: When it is motor inching time that means speed up and little time running, is 5 times bigger than rated current, contactor are closed and/or open can cause following defects or symptoms

3.1 wear and tear 3.2 dis-uniforming3.3 Silver alloy melts and spread out 3.4 Silver melted liquid drop down in fixed contact

3.5 many wear tear at the top of the moving contact3.6 it can see melted silver uniformly spread on the base plate of moving contact3.7 Also it can see blue color silver sulfate, well known that silver brightness parts3.8 crack lines on the contactor when it is open/close time so much.

Find out the basic trouble and maintain as so many times to get correctly.

4. Close/Open at Over rush current : Contactors are open/close at 10 times of rated current can get following defects or symptoms.

4.1 it is rising that surface roughness.4.2 All surface become brightly silver color.4.3 It can see arcing amount.

It may be interrupted at harzard severe time like short circuit.Find out the basic trouble/reason and remove it furthermore normal maintaining.

5. Un-completely Closing : There are following three reason of the contactors' nature.5.1 Less voltage and incompletely closing5.2 Under voltage supply and incompletely closing contact symptom5.3 Wear and tear for contactor vibrating.

5.1 Less voltage and incompletely closing: It can get enough magnetic attractive force that 85% of rated voltage. But supply side drops severely causes very low magnetic attractive force and happen that incompletely closing of contactor.

Also motor vibrating can get that loss voltage and contactor vibrated. So that contactor closes and opens so fast and contact burnt by arcing heat.

Although supply voltage enough or complete , wire so long and/or under size(very small, very high resistance) can also be incompletely closing.

It is bigger than 5 times of rated current when 3 phase induction motor direct starting time. If it is used very small size wire in circuit, terminal voltage of magnetic coil may be lower than 85% of rated supply voltage. So it's voltage loss cause can not close completely and can see contacts vibration.

Normally motor start to run slowly and smoothly, very short time current flow like that and then starting time finish and current drop until normal rated current. In this way voltage becomes normal rated voltage and electro magnetic contactors are in enough voltage and continue.Sometime it may be combine effect that supply voltage drop and wire size so small.

5.2 Under voltage supply and incompletely closing contact symptom : Wear and tear at contact top part that means it is can not move to top part until contactor are suppressed.Wear and tear the whole surface.Especially center area roughness is higher.It can see specially un-uniforming.Edge of the contacts becomes like flowers.Sometime base plate of the contact burn by heat flow by contact.Sometime it is change in color.

5.3 Wear and tear for contactor vibrating: A electro magnetic contactor performs together with auxiliary relay, plugging relay, and thermostat. So if their vibrations effect to contactor vibration by voltage unstable. Until good condition of contactor is unstable close and vibrate in very short period and then completely close.It is bigger arcing in starting than stopping.

6. Contact Changing or Replacing: Normally it is assume that contact changing time by daily using times and number of days. But it should not decide that normal performing facts.It should decide contact changing time by wiping drop and amount of wear and tear.Normally top part of contact wear and tear is small so that it must decide by wipe condition.If something special using also consider that top part wearing.

7. Wipe : Moving of contact base starts to end. Until contact moving finished, base continuously moves therefore spring pressure increase until base stop. The moving force can get from electro magnet. When contact wear , wipe less and pressure drop.

Rated lowest level of wipe value is 0.3mm or 1mm or 1.5mm to 2mm etc.

Note: Arc shield should change new one when contact changing otherwise short circuit in normal condition.If it rust on contact of electromagnet surface, clean by dry clothes . Don't scratch surface, otherwise it can be

humming. Normal rusting also does normal performance.If it wants to stop long time, it is to coat little by low viscosity transformer oil to prevent rusting.It is not stick dirt on electromagnet axis by blower. Otherwise it is humming by dirt on surface.

CONTACTORS TROUBLE SHOOTING

Sr.No Problem Relation Possible Case To Operate Remark1. Contact not

closeCoil very hot 1.1. Supply

voltage so low

1.2. Unstable supply voltage

1.3. Volt variation so much in circuit.

Discuss with Electrical supply department.

Voltage drop so high by not only load but also current.

Power line very long or very small size of wire.

1.4. Damage (mold etc.)

1.4. Repair it or change new one.

1.5. Loose connection

1.5. Reconnect back tightly.

If it tight nicely, it cannot loose anymore.

1.6 Loose contact 1.6 Repair it or change new one.

1.7 Contact vibrate

1.7 Repair it or change new one.

Lousy float switch, plugging switch can be made vibration and misunderstanding to electro magnetic starter.

1.8 Relay operated 1.8 Find troubles and maintain it.

Supervisor never experience trouble is in misunderstanding assumes that overload, relay operates, and can not switch on. Press reset buttons and starts again.

1.9 Line opens or ground to operate circuit.

1.9 Correction to right circuit.

It is not so easy to find out the trouble, so that misunderstand the basic reason.

1.10 Wrong connection in circuit

1.10 Re arrange that to get correct circuit connection

2 Contact vibrate Melting and mis positioning

2.1 Supply voltage very low.

Discuss Electricity Supply Department.

Informally wear and tear.

2.2 Unstable supply voltage.

Over volt drop by load current + starting current.

2.3 Unstable circuit voltage

Power line very long or very small wire size causes volt drop in starting time.

2.4 Loose connection

Connect firmly. If it is firmly tighten, it can't loose washer and spring anymore.

2.5 Contact vibrate Repair it or change to new good one.

Starter may misunderstand that effects of lousy float switch, plugging relay etc.

3. Over attractive force.

3.1 Over voltage and frequency.

3.1 Use correctly.

3.2 Open line or short circuit in coil.

3.2 Repair it or change new good one.

3.3 Dirt in contactor unit

3.3 If possible assemble in dirt free

It may be explode when dirt so many inside. Also problem in moisture and dirt mixing

area or use dirt proof type

environment.

4. Noisy in operation.

4.1 Supply voltage very low.

4.1 Discuss with Electricity supplier

4.2 Over voltage or frequency.

4.2 Use correctly.

4.3 Line open or short circuit in coil.

4.3 Repair it or change new good one.

5. Contact melting and mis-positioning

Circuit not open

5.1 So many contacts operating times

5.1 Discuss with company agent.

5.1 It may be possible for plugging and inching operation nature.

5.2 Short circuit at load side.(fuse not include)

5.2 Find out basic problem and repair it, also use good enough protective fuses.

6. Informally wear and tear.

6.1 Operated voltage or frequency not corrects.

6.1 Use correctly.

6.2 Phase out, run reverse a bit and over rated current running.

6.2 Discuss with sale agent or technical agent.

6.2 To select that first class of interruption in plugging and inching.

6.3 So much times open and close.

6.2 Discuss with sale agent or technical agent.

6.3 Over plugging and inching effect to contactors.

6.4 Oil dirt stuck on the contact surface.

6.4 Take care about wiring for oil using machine.

6.5 Short circuit at load side (fuse not include in short ckt)

6.5 Find out the primary problem and repair it and use enough fuse size.

6.5 Thimble overload relays can not protect to short circuit. Also wire fuses are weak to blow out so it can not interrupt the circuit that means it is assumption that no fuse include in circuit

7. Circuit or contact not open

operate very easy

Heater burn out (mold)

7.1 Damage mold etc.7.2 Iron core clearance so small

7.1 Repair it or change new good one. 7.2 Mechanical life time finished

7.3 Dirt inside contactor unit.

7.3.1 Fixing in dirt frees area or use dirt proof type.

7.3.1 If textile factory area, dirt inside contactor can be exploded also the factory that moisture filled dirt can get the problem.

7.4 Contactor's iron surface oil dirt stuck

7.4.1 Fixing in dirt free area or use dirt proof type

7.4.1 Machine that oil using should take care about wiring connection, and wiring.

8. Contact open time very long

Very easy to perform

Heater burns out that means very hot mold unit.

8.1 Very little core clearance

8.2 Contactor's iron surface oil dirt stuck

8.1 Repair it or change good new one

8.2 Fixing in dirt frees area or use dirt proof type.

8.1 Mechanical life time finished

9. Short circuit in phase contact

9.1 Dirt inside in contactor unit

9.1 Fixing in dirt free area or use dirt proof type

9.1 If textile factory area, dirt inside contactor can be exploded also the factory that moisture filled dirt can get the problem.

9.2 Over closing time in contactor

9.2 Discuss with manufacturer's agent

9.2 Plugging and inching operations can be damage to contactor.

9.3 Mold damage 9.3 Repair it or

change new good one.

9.4 Other operating circuit trouble


9.4 It is very complex in control equipment so not very easy to find the problem therefore it can miss the main reason.

10. Thermal OL very easy to work

10.1 Over closing time in contactor



10.2 Very long time taking in starting time


10.2 Like fan, pump or car

10.3 Over calibration to relay.

10.3 Re do it correctly.

10.3 Calibrate as load limit, special scale calibrating should be mark as proportion.

10.4 Contactor fix at Very vibrate place

10.4 To fix at low vibrating or no vibrating places.

10.4 It is no problem for 1mm/1.200min vibrating place.

10.5 Overload for contactor

10.5 Find out the trouble and repair it.

10.5 Press reset for contactor crazy.

11. Thermal overload no working

11.1 Over calibrating

11.1 Re do it correctly.

11.1 Calibrate as load limit, special scale calibrating should be mark as proportion.

11.2 Other operating circuit trouble


11.2 It is very complex in control equipment so not very easy to find the problem therefore it can miss the main reason

12. Heater burn out that means mold very hot. It is thermal OL relay problem

12.1 Over work for contactors.



12.2 Short circuit at load side that means not include fuse.

12.2. Find out the main reason and use reliable fuse type and size

12.2 Thermal OL relay can not protect for short circuit. Wire fuse is low explosive so that it can not blow out, therefore it is not include fuse in circuit.

It should be change contactor that 2/3 of the contactor's silver coated wearied. It is sure damage with stuck that it only left Cu contacts.

MAGNETIC DISC BRAKE TOUBLESHOOTINGSr.No. Trouble Cause Remedy

1. Not attract to armature or a little attract it.

1.1 No terminal voltage or not enough very low in terminal voltage.

1.1 Check out the electric circuit and repair it.

1.2 Coil broke 1.2 Troubleshooting and repair it.1.3 Foreign materials are place in armature and core surface

1.3 Clean it

1.4 Very big airgap 1.4 Measure and re-calibrate back2. Armature cannot pick

off.2.1 Electricity cannot stop 2.1 Check out the electricity and repair it.

2.2 It is not smoothly turn armature or lining holder.

2.2 Dismantle it and release the parts which are over tightened.

2.3 Foreign material inside.

2.3 Dismantle and clean it.

2.4 Internal burning 2.4 Dismantle and check it out, if it very difficult to repair, replace good new one.

2.5 Over voltage. 2.5 Check out the circuit and correct it.3. Magnetic coil burns

out.3.1 Short circuit in coil 3.1 Change new brake or new coil.

3.2 Counter voltage come out

3.2.1 Check reverse voltage protecting resistor and repair it if damage.

3.2.2 Change brake.3.3 Slip and overheat. Check the brake and find out the trouble as follows.

3.3.1 Armature attraction.3.3.2 Low brake torque or very less brake torque.3.3.3 Other type load using or not.3.3.4 Many time performing need it or not.3.3.5 Overlap motor and brake torque.3.3.6 Lining burns out.

3.4 Over heat in idling torque.

3.4. Recalibrate back to surface clearance.

3.5 Very low brake torque Check it out as follows 3.5.1 Very big gap3.5.2 Very weak in spring pressure.3.5.3 It is not proper fitting.3.5.4 Wrong selection brake size3.5.5 Lining wet by oil.

4. Over slip or it cannot perform fast.

4.1 Vary in load condition Check it out as follows4.1.1 Load increase by 6D2

4.1.2 Increase speed rpm4.1.3 Increase in repulsion force

4.2 Lining burn out 4.2 Find out the basic reason and change the lining.4.3 Overlap with motor and bake torque

4.3 Check the basic reason and if it needs time different between motor and brake.

4.5 Slip and overheat 4.5 Check out similar manner4.6 Short circuit in coil. 4.6 Change new brake or coil.

5. Very hot brake housing.

5.1 Very high terminal voltage

5.1 Check it out the electric circuit and repair it.

5.2 Overheat at normal no load

5.2 Check out surface clearance and adjust it.

5.3 Wear and tear in brake housing thread and friction disc.

5.3 If it is possible repair it otherwise change new good one.

6. It is too heavy to turn to friction disc

6.1 Catch by brake 6.2 Release it

6.2 Spread out the thread 6.2 Cool it and turn it.

CAPACITOR MOTOR

Analyzing Motor Trouble

1. Inspect the motor for mechanical defects.

2. Test the motor for bearing troubles.3. Test for ground, shorts.4. Running test for noise, speed etc.5. Capacitor must be tested

Rewinding

1. Taking data.2. Stripping the winding3. Insulating the slots.4. Rewinding5. Connects the winding.6. Testing.7. Braking and varnishing.

Common Reason for Capacitor Failure

1. Stuck or fused contacts on the switch on relay.

Result : Continuous application of voltage to the capacitor.2. Worn or frozen bearings on the motor.3. Excessive load on the motor.

Result : this prevents the motor from starting or from reaching full speed.4. Incorrect capacitor rating.

Reason: Too large or too small a capacitor will produce a decrease in the starting torque.5. Incorrect voltage rating of the capacitor.

notice: the voltage rating of the capacitor is much higher than the voltage rating of the motor, higher voltage capacitors can be used to replace units with lower voltage ratings.

6. Lower line voltage.Reason : low line voltage into the motor may cause the motor to continue running on the starting winding capacitor in the circuit longer than permitted by its maximum duty cycle.

7. Shorted capacitor case.

Testing the capacitor

1. Fuse burn out test for shorted capacitor. 10A fuse across 115V, 60Hz power line .

2. Shorted by screwdriver.

3. Capacity test : Using ac voltmeter (||) & ac ammeter (series).

Capacity in uF = 159300 x Amperes / (Frequency x Volts)

4. Test for open : Using ammeter.

5. Test for shorts : Fuse burn out

Using test lamp in series

6. Test for Ground : Using test lamp.

7. Test for winding : * Grounds test

Shorts test Opens test Reverse test.

Sr.no. Trouble Possible Case Cause Remedy1. The Capacitor start

motor fails to start1. Defective Capacitor. Same as the

split phase motor.

1.Test the capacitor.

2. Burn out fuse -----||------ 2. To find cause.3. Opens windings -----||------ 3. Test for open using

test lamp.4. Centrifugal switch -----||------ 4. Exchange.5. Shorted winding -----||------ 5. Short test6. Worn bearing -----||------ 6. Exchange7. Overload -----||------ 7. Search

2. The motor hums and then blows a fuse shortly after current is applied.

1. Defective capacitor short.

starting winding circuit will be in

* Test Capacitor

* Replace capacitor

2. Defects capacitor opens operative

3. Loss of capacityand motor not starting

Permanent split capacitor motor expects the centrifugal switch will not be encountered.

Two-value Capacitor Motor

Sr.no. Trouble Possible Case Cause Remedy* Electrolytic capacitor Prevent the starting Starting capacitor should be replaced.

defective. orNot run perfectly

Running capacitor failure with slightly lowered efficiency.

Two-value Capacitor -transformer Motor

Sr.no. Symptom Possible Cause Cause Remedy1. Fail to run Defective capacitor -

transformer unit.Capacitor or transformer both or one may break down.

To remove the transformer & replace it with an electrolytic capacitor.

2. Efficiency slightly less and not run as quietly.

Lower the capacity. Difficult to determine.

* New capacitor change and see carefully* Measure by ammeter if torque is the highest, the lowest current in flow.

General trouble and Symptom for Capacitor Motor

Sr.no. Symptom/Trouble Possible Case1. Poor Starting Torque or

starts with difficulty(a) Defective Capacitor(b) Worn Bearing(c) Shorted winding(d) Wrong connections

2. The Fuse Burn out when current is applied to the motor

(a) Shorted winding(b) Started capacitor(c) Open winding(d) Grounded winding(e) Overloaded(f) Badly worn bearings(g) Defective centrifugal switch(h) Wrong in pole connection

3. The motor hums but doesn't run.

(a) Defective capacitor (b) Open/Short starting or running winding Overload(d) Miss alignment in rotor (Rotor apmif;ae^cif;)(e) Miss alignment in shaft (Shaft aumufae^cif;)(f) Bearing so tight. (Bearing }uyfae^cif;)(g) End plate miss position (End plate txdkifrus^cif;)

4. Smoke from a motor while running

(a) Shorted windings Failure of centrifugal switch to open starting winding circuit.(e) Bearing trouble.(f) Overload(g) Defective auto transformer.

5. Higher temperature than normal temperature

(a) Winding turn wrong (less winding turns)(b) Winding wire size so small (Checking as table 3.) Tight with rotor and stator(e) So less in grease in bearing

6. Higher than normal speed (a) Wrong in pole connection or shorted(b) Over supply voltage

7 Starting torque less (a) Check starting capacitor value(b) Starting winding turn short Overload

8. Slower than normal speed (a) Starting winding include running time by centrifugal switch.(b) Wrong pole connection or Shorted. Bearing clearance. see table 1.

SPLIT PHASE INDUCTION MOTOR

Motor Testing

Grounds : 1. Bolt of the end plate tight to winding and winding damage.

2. Windings and slot edge tight, when windings were placed.3. Centrifugal switch ground to end plate , test by test lamp.

Open Circuit : 1. Loose connection or dirty connection.

2. Wire broken.3. Centrifugal switch open, tests by test lamp.

Short Circuit : 1. Windings are very hardly pressed inside the slots and very hardly tightened until cover enamel damage.

2. Excessive heat by overload symptom : Smoke from windings and overcurrent in noload.

Testing Procedure : 1. Motor run in short time and find out that which winding is the hottest.

2. Use internal growler.3. V drops test.4. Measure field strength by iron strip.5. Use ammeter

Reverse or Rotation : 1. The compass method.

2. The nail method.

Sr.no. Trouble Possible Case Test Method/Reason Remedy1. Motor fail to start 1.1 Open running

coilTesting the winding with test lamp.

Repair by rewinding if necessary.

1.2 Open starting coil

1.2.1 To connect the motor to power line. An open circuit starting winding will cause to the motor to hum

1.2.2 Turn the rotor by manual and switch turn on, if motor continue to run the trouble is starting winding open

1.2.3 To use the test lamp

c.w switch open or starting winding open.First : Centrifugal switch test.Second : Starting winding test.

May be repaired by splicing if it readily accessibly Rewinding is necessary if the coil is burned or severely damaged. . To test the running winding for anydefects before replacing the starting winding over it

1.3 Grounded winding

1.3.1 Fuse blow when 2

or more ground or smoke

1.3.2 Test lamp method

1.3.3 Use internal glower.

Exchange the winding.

Insulation adding for small case.

1.4 Burned or 1.4.1 Fuse blown In many case only stating winding

shorted winding 1.4.2 The winding

will smoke.

1.4.3 Smell out and its

burned appearance

will be burned and need to rewind

The running winding should be tested before install the new starting. winding.

1.5 Open circuit OLs devices(which connect series with motor)

1.5.1 Overload1.5.2 Too much

current flow through winding

1.5.3 The contacts are examined for dirty, defective or burned points.

If the contact points are in bad condition they should be replaced with new ones.

1.6 Excessive over load

1.6 By connecting an ammeter in the ckt<snap around volt, ammeter, ohmmeter can be used > A short winding cause large reading.

Cut out the overload and search for the overload source & repair it.

1.7 Worn or tight bearing.

1.7.1 To move the shaft up and down by hand.

1.7.2 A small amount of plays the bearing low rotor touch stator.

1.7.3 Sludge may prevent an up and down motion of shaft.

1.7.4 The shaft of rotor is worn.

New bearings are required. Sleeve bearing is removed by means of arbor or

some other press/new sleeve bearing replace. Motor is disassembled so that the rotor is resting

in one end plate. It may be reconditioned to its original roundness

and smoothness by turning it in lathe (metallization method used by forcing molten metal on it )

1.7.5 Frozen bearing (little grease in bearing so molten by bearing heat)

Loose to shaft by blow touch and then replace new bearing.

1.8. End plate improperly mounted.

1.8.1 The bearing is out of alignment.

1.8.2 The rotor turned by hand difficulty or not at all.

1.8.3 Using mallet hammer or lead hammer and listen The sound solid.

If end plate does not fit, all screwed should be loosened and each one tightened a little at a time and drawing the plate evenly and securely to the stator. In assembling first screw on, adjacent screw on not tightly first and step by step tight.

1.9 Bent rotor shaft.

1.9.1 Rotor doesn't turn

easily by hand.

Rotor is removed from stator and placed in lathe (see in page 45.)

2 Motor run slower than normal speed

2.1 Short circuit in running winding.

2.1.1 To run at a lower speed.

2.1.2 Humming or growling noise

2.1.3 The pole contains the short will usually become excessive hot and smokes.

To find the short and after it is found. Insulate it if possible. If it cannot be insulated, rewind the coil or the

entire winding.

2.1.4 To locate the shorted pole by an internal glower is used.

2.1.5 Pole may be located by merely feeling for the hot coil.

2.2 Starting winding remains in the circuit.

2.2.1. Same symptom for shorted running winding.

2.2.2. Take off starting winding and run it, if cw s/w ok and run properly means starting winding not properly working.

2.2.3. Contact points were welded or stuck.

2.2.4. Fiber washer is not proper position on the shaft.

Replace new c.w switch. Place fiber washer as correct position.

2.3. Reversed running winding poles.

2.3.1 Incorrect polarity.

2.3.2 Growling noise.2.3.3 Each pole tested

by compass or nail test.

When the improper polarity is located, the lead wire of the pole are disconnected, reversed and reconnected.

2.4. Other incorrect stator connections.

2.4.1 Induced current to flow in the pole coils overheated, smoke and burn out.

To connect all poles exactly as required by data.

2.5 Worn in bearing

2.5.1 Noisy in operation.

2.5.2 Sluggish in rotation.

2.5.3 Rotor rubs against the stator while running.

2.5.4 Motor shaft moved up and down test.

Same as upper worn bearing case.

2.6 Loose rotor bars

2.6.1 The motor runs with reduced power.

2.6.2 Growling noise.2.6.3 Visual

inspection.2.6.4 Using armature

glower (or external glower) flicker of the series lamp indicates open bar.

Solder or welded to the end rings. Rotor with a die cast aluminum squirrel Cage does not have this defect.

3 Motor runs hot 3.1 Shorted winding 3.1.1 Shorted pole will become excessive hot.

3.1.2 Growling noise.3.1.3 Testing shorts

for locate and short circuit exists.

Can be repaired and insulated the pole. The entire winding must be rewound.

3.2 Grounded 3.2.1 Two or more Re-insulating if possible.

winding ground is equal to short.3.2.2 To run very hot.3.2.3 Severe damage.3.2.4 Use test lamp.

If impossible the grounded pole must be rewound. If one point ground immediately repair is essential.

3.3 Short circuit between running and starting winding.

3.3.1 Will be burn out the starting winding .

3.3.2 Use test lamp to starting winding terminal and running winding leads.

The starting winding is moved away from running winding. Winding and various places in the stator . If the shorted point is moved, the lamp will flicker or go out. Use short point method to find the location , if it cannot use other method as take off starting winding and find out. A strip of varnish cambric or Armo paper was put between two windings.

3.4 Worn bearing. 3.4.1 Rotor touches to stator.3.4.2 Over heat when it is just run.3.4.3 Move rotor shaft up and down.

Polish surface on it. If rubbing against the stator, replacing the bearing.

3.5 Overload 3.5.1 Draw more than rated current .3.5.2 Procedure excessive heat.3.5.3 Ammeter test.

The load should be reduced. Motor replaced with large one.

4. Motor runs noisily that means unusual amount of noise.

4.1 Shored winding.4.2 Poles are connected improperly4.3 Loose rotor bar

||| Produce magnetic hum||

Follow above methods.

4.4 Worn bearing Allow the rotor to rub against the stator.

Follow above methods

4.5 Worn centrifugal switch

4.5.1 Some parts of centrifugal switch are not separate in high speed, so it is touch to rotor and noise.4.5.2 Loose member of rotating part hit or rubs to one part of motor.

Disassemble rotor and check centrifugal switch which you suspected.

Repair the damage part. If cannot repair replace by new one..

4.6 Too much end play..

Something plays more than 1/64" become noise.

Put Fiber washer in require place of rotor shaft.

4.7. Foreign material in rotor.

It may be pieces of wire or insulation touch to rotor and it makes noise.

Disassemble motor and remove by pliers or screw driver carefully that its don't damage the windings.

POLYPHASE INDUCTION MOTOR

#Testing

*Grounds Test * Disconnect the star point for each winding.

Disconnected the jumpers between group of the coil windings. Opening the coil splices Search ground. Reinsulated the slot or new coil in the stator.

*Open Circuit Test

Break in the coil.

Loose connection at the splices or jumpers. Use test lamp and determine phase open. Reconnected and soldered and tape.

*Shorted Circuit Test * Use internal growler. Operate the motor for a few minutes. Search for the hottest coil group. By means of ammeter (clip on type motor) in each phase (balance test) Higher reading phase is shorted.

*Reverse Test * Reverse coil - Compass needle method.

Reverse coil group - Compass needle method. Reverse phases - Compass needle method.

Sr.no. Symptom/Trouble Possible Case1. Fails to Start 1.1. Burn out Fuse

1.2. Worn bearings.1.3. Over load1.4. Open phase.1.5. Shorted coil or group1.6. Loose rotor bars.1.7. Wrong internal connection.1.8. Frozen bearing.1.9. Defective controller.1.10. Grounded windings.

2. Not run properly 2.1. Burn out Fuse.2.2. Worn bearings.2.3. Shorted coils2.4. Reversed phase.2.5. Open phase2.6. Open parallel connection.2.7. Grounded windings.2.8. Loose rotor bars.2.9. Incorrect voltage or frequency.

3. Runs slowly. 3.1. Shorted coils or groups.3.2. Reversed coils or group.3.3. Worn bearing.3.4. Overload.3.5. Wrong connection (reversed phase).3.6. Loose rotor bars.

4. Excessively hot. 4.1. Overload.

4.2. Worn bearing 4.3. Tight bearing.4.4. Shorted coil or group.4.5. Motor running on single phase.4.6. Loose rotor bars.

#Remark

Burn Out Fuse: * Remove fuse.

Test with test lamp ( light means good, no light means bad ) Don't remove fuse. Switch closes and test with test lamp. ( light means bad, no light means good ) Winding become very hot and noisy and not pulls the load.@ Remedy : Locate and replace the defective fuses.

Worn Bearings:

@ Cause :* Rotor will ride on the stator and cause noisy operation.

If bearing are so worn rotor rest firmly on the stator and impossible to run.

@ Check: * Try moving the shaft up and down.

Remove and inspects for the rotor for smooth, worn spots.@ Remedy: * The only remedy is to replace the bearings. A large motor is made with feeler gauge. The air space between the rotor and the stator must be the same at all points

for not replaces bearing.

Overload:

@ Check: * Remove the load or belt.

Turn on the shaft by hand usually a broken past or dirty mechanism will prevent the shaft from moving freely. To connect the ammeter in series with each live wire ( snap-around-voltmeter and ohmmeter to test ). The current in

the nameplate is same as the reading. Excessive reading is one phase short. To test voltage, resistance and current.

Open Phase

@ Cause: * Motor will continue to run but have less power.

Broken wire in-group of coil or a loose connection.

@ Remedy : * Locate the open coil.

Rewinding the open coil or if it is possible, connect the open point. The motor will continue to run if phase open, but will not start if at standstill, conditions are similar to those of a

blown fuse.

Shorted coil or Group

@ Cause : * Noisy operation.

Smoke. When insulating enamel on the wire fails, individual turn become shorted and coil extremely hot and burn out.

@ Check: * Locating defective coils by means of the eye or balance test.

By means of the growler.@ Remedy: * Cut the entire coil at one point at the back and twist the turn on both sides. Be certain the turns are free

of insulation before wire twist.

If an entire group is burn out the motor should be rewound.

Loose Rotor Bars

@Cause: * Produce noisy operation.

Spark may be seen between the bars and end rings while the motor is running. The motor may not rotate.@Check: * Glower and hacksaw use to test.@Remedy: * Resoldering or welding.@Notice: * Not use above procedures for a die cast aluminum winding.

Wrong Internal Connections

@Check: * Remove motor.

Place large ball bearing in the stator. Switch is closed to supply current to the winding. If connection wrong, the ball bearing will remain stationary.@Remedy: * For medium and large sized motors should be used reduced voltage or a fuse may

blow.

Reconnect the connection as data of coil.

Frozen Bearing

@Cause: * Oil or Lubrication oil is not supplied or not sufficient.

Expansion the bearing by heat and may weld to the shaft. Impossible to rotate.@Remedy: * The shaft has to be turned down on a lathe to the new size and new bearing made.

If ball bearing are used replace with new ones.

Defective Controller

@Cause: * The contacts on the controller do not make good contact.

The motor will fail to start.

Grounded Windings

@Cause: * When motor is touched, it will produce shock.

Grounds are more than one place, it is equal to short circuit and fuse will blow.@Check: * Use by test lamp.@Remedy: * Repair by rewinding.

Replacing the defective coil.

Reverse Phase

@Cause: * To run more slowly than rated speed.

Produce an electrical hum indicative of wrong connection.@Remedy: * Check the connections and reconnect them according to plan.

Open Parallel Connection

@Cause: * A noisy hum.

It will prevent the motor from pulling to full load.@Remedy: * Check for complete parallel circuit.

AC MOTOR CONTROLLER

Sr.No. Trouble Possible Cause1. Motor doesn't start when the

main contact close.1.1. Open OL heater coil or poor connection.1.2. Main contacts not making.

1.2.1. One or contacts wear sufficiently.

1.2.2. Dirty.1.2.3. Gritty.1.2.4. Burned.

1.3. Broken, Loose or dirty terminals connection.1.4. Dirty or broken pigtail connection.1.5. Open resistance unit or open autotransformer.1.6. Obstruction on the magnet core, preventing the contacts from closing.1.7. Mechanical trouble, mechanical interlocks, gummy pivots, poor spring tension so

on.2. If the contact does not closed

when the start button is pressed.

2.1. Open holding coil ( Test by test lamp )2.2. Dirty start button contacts or poor contact2.3. Open or dirty stop button contacts ( More than one station, check each station.

For forward-reverse station, interlocked, check all contacts )2.4. Loose or open terminal connection.2.5. Open OL relay contacts.2.6. Low voltage.2.7. Shorted coil.2.8. Mechanical trouble.

3. The contacts open when start button is released.

3.1. Maintaining contacts that don't close completely or are dirty, pitted, or loosed.3.2. Wrong connection of station to the controller.

4. Fuse blow when start button is pressed.

4.1. Grounded contacts.4.2. Shorted coil.4.3. Shorted contact.

5. The magnet coil is noisy in operation.

5.1. Broken shaded pole causing chattering.5.2. Dirty core face.

6. Magnet coil is burned or shorted.

6.1. Overvoltage.6.2. Excessive current due to a large magnetic gap caused by dirt, grit or mechanical

trouble.6.3. Too frequent operation.

Testing

Opens Shorted resistance Shorts Low voltage Grounds High voltage Continuity Excessive amperes. Shorted coils Broken connection Open coils Dirty connection Grounded coils Loose connection Open resistance Many other mal-functioning component may be tested with

comparative case

Lightning Calculation

1. There are 2 types in lightning cable, Cu and Aluminum.2. When roof is metal sheet , It should use Aluminum cable .3. Lightning tape standard size is 25mm width x 3mm thickness.4. Earthing should be normal earthing system, then standard amount of resistance is Re < 105.

BI (Junction) Earth Spike or Earth Plate Cu.

6. Standard Lightning final is a 300mm or 600mm long Cu final etc.

Allowable Cable Bending

R < 6D Where R is Bending RadiusD is Diameter of the cable( outer )

Conduit Size Calculation.Space factor : - The ratio of the total CSA of cables to the CSA of the conduit housing;

it is expressed as a percentage . The stated maximum value for conduits is 40%.

CSA CablesSpace factor =

CSA Conduit

e.g. What size of conduit is required for 4x2.5mm2 & 4x6mm2 PVC cables.

100 x CSA cablesCSA Conduit = mm2

40 = 100/40(4x0.7854 x3.52 + 4x0.7854x4.92)

0.7854 Conduit Diameter = 10 x 0.7854 ( 3.52 + 4.92 )Conduit Diameter = 362.6 = 19.1 20mm

IEE Table B.5MNominal Conductor Size (mm2)

Number & Diameter of wire (No/mm)

Nominal Overall Diameter (mm)

1.0 1/1.13 2.91.5 1/1.38 3.12.5 1/1.78 3.52.5 7/0.67 3.84 7/0.85 4.36 7/1.04 4.9

Power DistributionIEE Definition Range of voltage1. Extra Low Voltage (ELV)

0-50 VAC or 0-120VDC between conductor to earth.2. Low Voltage (LV)

above ELV to 1KV AC(1500Vdc) between conductors or 600V AC (900Vdc) between conductors & earth.

3. Extra high pressure : above 3KV4. Variation : 6% for voltage.

1% for frequency.

Think Effect for design the substation1. Electrical Single Line Diagram.2. Floor Area ( standard BS area is 20m2for every one transformer)3. Height (lift enough height is 2.75m)4. Roof5. Doors ( normally it is heavy aluminum louver door or heavy duty aluminum door)6. Ventilation ( artificial heating & moisture during winter )7. Natural light ( desire ) & some form of light ( secondary )8. Fire Risk

8.1 Ignition oil in transformer and CB8.2 Transformer short circuit in winding.8.3 Oil vaporize and lose connection => expansion.8.4 CO2 fire extinguisher use.

9. Package substation ( dry type transformer and ACB up to 1600A to avoid oil explosion )

10. To lay cable trench 0.76m depth & 0.76m wide, covered with heavy duty MS plate or Steel plate ).Busbar SizeBusbar Size Ampere Busbar Size Ampere1/8 x 1 (inch)3.2 x 25.4 (mm)

125 1/4 x3/4 (inch)6.4 x 19 (mm)

187

1/8 x 1-1/2 (inch)3.2 x 38 (mm)

187 1/4 x 1 (inch)6.4 x 25.4 (mm)

250

1/8 x 2 (inch)3.2 x 51 (mm)

250 1/4 x 1-1/4 (inch)6.4 x 32 (mm)

315

3/16 x 1 (inch)4.8 x 25.4 (mm)

187 1/4 x 1-1/2 (inch)6.4 x 38 (mm)

375

3/16 x 1-1/2 (inch)4.8 x 38 (mm)

281 1/4 x 1-3/4 (inch)6.4 x 45 (mm)

437

3/16 x 2 (inch)4.8 x 57 (mm)

374 1/4 x 2 (inch)6.4 x 51 (mm)

500

1/8 x 5/8 (inch)3.2 x 16 (mm)

78 1/4 x 2-1/4 (inch)6.4 x 57 (mm)

562

1/8 x 3/4 (inch)3.2 x 20 (mm)

100 1/4 x 2-1/2 (inch)6.4 x 63.5 (mm)

625

3/8 x 1 (inch)9.5 x 25.4 (mm)

375 1/4 x 3 (inch)6.4 x 76 (mm)

750

3/8 x 1-1/4 (inch)9.5 x 32 (mm)

470 1/4 x 4 (inch)6.4 x 102 (mm)

1000

3/8 x 1-1/2 (inch)9.5 x 38 (mm)

560 1/2 x 1 (inch)12.5 x 25.4 (mm)

500

3/8 x 1-3/4 (inch)9.5 x 45 (mm)

655 1/2 x 1-1/4 (inch)12.5 x 32 (mm)

625

3/8 x 2 (inch)9.5 x 51 (mm)

750 1/2 x 1-1/2 (inch)12.5 x 38 (mm)

750

3/8 x 2-1/4 (inch)9.5 x 57 (mm)

840 1/2 x 1-3/4 (inch)12.5 x 45 (mm)

875

3/8 x 2-1/2 (inch)9.5 x 63.5 (mm)

935 1/2 x 2 (inch)12.5 x 51 (mm)

1000

3/8 x 3 (inch)9.5 x 76 (mm)

1120 1/2 x 2-1/2 (inch)12.5 x 63.5 (mm)

1250

3/8 x 4 (inch)9.5 x 102 (mm)

1500 1/2 x 3 (inch)12.5 x 76 (mm)

1500

2 x 9.525 x 101.6 3000 1/2 x 4 (inch)12.5 x 102 (mm)

1995

Note: Conversion ratio 1/8 = 15.6251mm2 = 1.55

Battery (Vehicle)Symptoms Faults Causes1. Battery does not hold charge

1.1 Excessive demands on battery. 1.1 Overloading of electrical system

1.2 Current leaking away externally.

1.2 Stop light staying on wiring faults

2. Specific gravity constantly low

2.1. Battery discharging back by generator.

2.1. Generator cut out opening.

2.2. Local action in cells 2.2. Impurities in electrolyte.3. Light dim 3.1. Internal short circuit in one or

more cells3.1. Worn out separators buckled plates, Sediment shorting bottom of plates

3.2. Insufficient charging 3.2. Generator or regulator faulty abnormal running conditions

4. Voltage 1.8 or less per cell on headlight discharge

4.1. Defective cell 4.1. Internal short between plates

4.2. Electrolyte lost 4.2. Cracked casing5. Two adjacent cells "dead" or reversed polarity.

5.1. Short between adjacent cells. 5.1. Cracked cell partition.

6. Low electrolyte level in one cell

6.1. Electrolyte leaking 6.1. Cracked container.

7. Frequent topping up necessary.

7.1. Battery being overcharge 7.1. Regulator faulty voltage setting too high.

8. Bulged container cell covers lifted

8.1. Buckled plates 8.1. Neglected maintenance

8.2. Fractured plate grids 8.2. Worn-out battery prolonged under charging.

9. Very hot & smelly 9.1. Acid weakness 9.1. Check battery acid level & intensity

9.2. Fill up acid in every 1-1/2 month or granted time.

Illumination&

LightingLight Source(a) Sun & Reflection from sunshine(b) Friction with materials(c ) Nuclear fusion(d) Coal, wood, gasoline etc. burning

Illumination TheoryLuminious Flux : Total emission of light within 1sec.

unit : 1 lumen = 1/60 watt .or. 0.00147 wattLuminious Intensity I : I = /w where w= 4 radian

unit : candela (cd) .or. candle power ( cp)Standard Candle : make by pure wax (ysm;za,mif;ppfppf)

7/8 in diameter 120 grains .or. 7.776 gm burning within 1 hr. time

Illumination ( E ) .or. ( P )E = /A where = Flux in lumen on surface area.

A = Working surfaceunit : lumen /ft2 => F.C .or. lumen/m2 => Lx (Lux) where 1 lux=0.093 F.C

Inverse Square Law Light Source

E I / r2 r

Working Surface

Lambert Cosine LawE = I Cos3 / d2

Utilization Factor .or. Utilization (Coefficient of Utilization )It is ratio of flux(0) which is flux emission by light source, and flux w direct down on the working plane.

= w / 0

Utilization is very important factor in Illumination & Lighting design.It needs to find out in table that color of room, maintenance factor, and light typical distribution .or. effective light percentage Lighting .or. Illumination SystemIt can use indoor .or. outdoor1. Direct System.2. Semi Direct System3. Semi - Indirect System.4. Indirect System.Table 39-3 from Gray & WallaceClassification Approximate distribution of light output of

luminaries percentUpward Downward

Direct 0 - 10 100 - 90Semi Direct 10 - 40 90 - 60Direct- Indirect ( General diffuse ) 40 - 60 60 - 40Semi-indirect 60 - 90 40 - 10Indirect 90 - 100 10 - 0

In G.T.I Course as British Standard1. Direct - 90% downward2. Semidirect 45% downward, 30% upward & the rest drop on wall.3. General Diffuse 40% downward, 40% upward & the rest drop on wall.4. Semi Indirect 10% downward, 75% upward the rest drop on wall.5. Indirect 80% , 90% upward & the rest distribute on floor & wall.

In R.I.T Course as SI unit

1. Direct 75% downward2. Semi direct 45% downward3. Direct & Indirect (General diffuse) 30% downward4. Semi Indirect 25% downward5. Indirect 20% downward

Maintenance FactorMaintenance factor depends upon cleaning condition of lighting fixture.This clearance depends upon amount of soiling(dust).I. Slight soiling .or. soiling rate low shops, office & schools.II. Normal soiling all other factories.III. Heavy soiling .or. soiling rate high blast, furnace factories, smith, mine & some department of textile factories.

A. Cleaning of lamps & fitting every year (end of year)B. Cleaning of lamps & fitting every 2 yearsC. Cleaning of lamps & fitting every 3 years

It is point number .or. rational number only.Maintenance factor inverse to D.F ( Depreciation Factor )Depreciation factor is full number.

Illumination Designing Steps ( Referred to R.I.T. 4th Year Course )Step.1.. Find out the Room index k = (2l + 8w ) / 10hStep.2.. Ceiling Reflection factor rc & walls reflection factor rw fixed and then find out from table.Step.3.. Find (lux) of TL rom table for lamp & fit & Step.4.. Find required illumination which effect to working plane by table ( E in lux )Step.5.. Find out numbers of fitting by

E x S x d.f E x SNfit = -------------- = --------------------

fit x fit x x m.fwhere d.f - depreciation factor from cleaning type & soiling rate.

1m.f = --------- = maintenance factor d.f.

Step.6.. Counter check - Find out 0 & 0 = Nfit x lamp x Nos of lamp / fit

0

Ew = ------------- Where S = Area in meter2

S x d.f. 0 =Normal Luminaries fluxCompare Ew & E of selected from table, if it is almost same Nfit can be accepted.

Step.7.. Arrange lamp fitting in Room

# 1 lumen = 1/680 watts or 0.0147 watt# I - luminous intensity in c.d. ( candela ) I = / w where w is solid angle# Lambert Cosine law - E = I/d2 x Cos # Slight soiling - shops, office, school, etc.

Normal soiling - All others factories Heavy soiling - Blast, furnace for dairies, smith, mines & textile Factories.

# Reflection factor ( absorption factor rc & rw ) a. White or very light color - 70%b. Light color - 50%c. Medium shades - 30%d. Dark color - 10%

# Twice of distance apart from wall & nearest fitting is equal to distance between fitting by fitting.# 1 lux = 0.093 F.C. ( foot-candle )# Working plane & E (F.C) ( 1-lux)

1. Drawing office - 50~100(75) F.C or 537.6~1075.3(806.4) lux2. General office(Precision) - 50(30) F.C or 537.6 (322.58) lux3. General office( Normal ) - 50 F.C or 537.6 lux

4. Book keeping/ Accountant / Typist - 50~100(75) F.C or 537.6~ 1075.3(806.4) lux5. Desk / Reading / Writing - 50 F.C or 537.6 lux6. Corridor & Stair - 2~10 F.C or 21.5~107.5 lux7. Hotel / Hospital & Stair - 5~10 F.C or 53.76~107.5 lux8. Classroom - 30~50 F.C or 322.5~537.6 lux9. Sewing (light color) - 50 F.C or 537.6 lux10. Sewing (Deep color ) - 200 F.C or 2150.5 lux 11. Manufacturing Factory(Base) - 30 F.C or 322.6 lux12. Manufacturing Factory(Normal)-50 F.C or 537.6 lux13. Manufacturing Factory(Precision) - 100~200 (150) F.C or 1075~ 2150 (1612.9)lux14. Hospital Operation table - 300 F.C or 3225.8 lux

# Hospital 1. Ward & private room - 3 F.C or 32.26 lux2. Waiting & receiving room - 7 F.C or 75.27 lux3. Operating table - 300 F.C or 3225.8 lux4. Operating room - 30 F.C or 322.58 lux5. Laboratories - 20 F.C or 215.05 lux

# Industries1. Assembling shop ( Rough work ) - 7 F.C or 75.27 lux2. Assembling shop ( Ordinary work ) - 10 F.C or 107.5 lux3. Assembling shop ( Medium work ) - 20 F.C or 215 lux4. Assembling shop ( Small m/cs ) - 50 F.C or 537.6 lux5. Assembling shop ( very small works) - 100 F.C or 1075.2 lux

# Glass work1. Mix & Furnace room - 5 F.C or 53.7 lux2. Glass Blowing m/c, Grinding, cutting / Glass to size, Silvering, Pressing - 10 F.C or 107.53 lux3. Fine, Grinding, Beveling, Inspection, Etching & decorating - 20 F.C or 215 lux4. Glass cutting, Fine inspection - 50 F.C or 537.6 lux

# Hotel 1. Lounge & Dining Room - 7 F.C or 75.27 lux2. Writing Room - 7 F.C or 75.27 lux3. General - 7 F.C or 75.27 lux4. Tables / Kitchen - 7 F.C or 75.27 lux5. Bedroom - 5 F.C or 53.76 lux

# Office & Bank1. General office works - 20 F.C or 215 lux2. Private Office - 15 F.C or 161.3 lux3. Typing & Bookkeeping - 20 F.C or 215 lux4. Filing - 20 F.C or 215 lux

# Chemical works1. Hard Furnace, Boiling Tanks, Stationary dries, Stationary or Gravity Crystallizing, Mechanical

Furnace, Generators & Still, Mech. Dryers, Evaporator, Filtration, Mech. Crystallizing, Bleaching- 7 F.C or 75.27 lux2. Tanks for cooking, Extractors, Percolators, Nitrators, Electrolytic Cells - 10 F.C or 107.52 lux# School1. Day Classroom - 15 F.C or 161.29 lux2. Drawing & Art - 20 F.C or 215 lux3. Gymnasiums - 10 F.C or 107.52 lux4. Laboratories - 15 F.C or 161.29 lux5. Lecture / Theatre - 10 F.C or 107.52 lux6. Manual Training - xxxxxxxxxxxxxxxxxxxxx7. Sewing - 20 F.C or 215 lux# Machine Shop & Fitting Shop

1. Ordinary bench & m/c work - 10 F.C or 107.52 lux2. Rough bench & m/c work - 10 F.C or 107.52 lux

3. Medium bench & m/c work, ordinary automatic m/c, rough grinding m/c, Fine Buffing & Polishing - 20 F.C or 215 lux4. Very Fine Bench & m/c works, Grinding (fine) - 100 F.C or 1075.2 lux

FLUORESCENT LAMPS ( S.E.E.)

Standard Fluorescent Lamp in Market Lamp Type Watt Nominal

luminous flux after 100 hrs of burning in Lux

White 33

Warmwhite 29

Daylight 55

Warmwhite White

deluxe 32 deluxe 34

"TL" 4W 1006W 2308W 370

13W 71020W 1080 1080 820 750 75025W 1650 1650 1250 1130 113040W 2800 2800 2120 1880 200065W 4400 4400 3300 3000 3200

"TL" D 15W 550 58030W 1350 1300

"TL" E 22W 75032W 1600 1700 1220 1300

"TL" EM 40W 2250 2380 1660 1800"TL" F 40W 2460

65W 4000"TL" M 40W 2650 2650 1780 1900

65W 4400 4400 3000 3100125W 7300

"TL" MF 40W 246065W 4000

"TL" S 20W 900 900 62040W 2300 2300

Table of Color comparison between hot cathode florescent tubesKelvinapprox.

American / Japanese(e.g. Sylvania)

English(e.g. Thorn-Atlas)

Australian(e.g. Phillips, Osram, Mazda, Crompton)

2800 Warm white Warm white -2900 - - Warm white3000 Warm white deluxe Warm white deluxe Warm white deluxe3200 Natural deluxe Natural deluxe -3500 White White White 3500K3800 Natural white - White deluxe4150 - - Kolor-rite4200 - Natural -4300 Cool white Daylight White6500 Daylight Tropical daylight Daylight

Comparison of light sources ( Following figures are an approximate general guide only)

SourceEfficacy

(l/W)Approx.life hrs

Lamp source

Relative cost

Incandescent 14 1000 60WCoiled coil

Low

Tubular fluorescent 65 7500 40WWhite

Medium

Mercury vapor (clear) 45 8000 250W MediumMercury vapor color-corrected 50 8000 250W MediumMV Metal halide 75 8000 400W HighLP sodium 130 6000 100W HighHP sodium 95 8000 400W HighTungsten halogen 28 2000 1000W Low

TROUBLESHOOTING FOR COMMON FAULTS IN LUMINAIRES( Adapted from table supplied by GTE Australia )

Problem System Possible Case Corrective maintenanceLamp fail to light

All Blown fuse or open circuit - breaker

Replace or reset as necessary. Look for possibles short-circuit in wiring or equipment.

Pre - heat Reset type starter not reset.

Reset manual type. If automatic type, extinguish circuit or remove starter from socket for approximately one minute, then re-energize circuit. If starter cuts out again investigate further. ( See other possible case in this section. )

All Wrong lamps Check ballast label, replace with correct lamp. Whenever practical, it is advisable to turn the power off before making a replacement.

All Poor contact between lamp and lampholder

Adjust lamp to seat it properly. Some two-pin lamps have two pits or marks on the base , which are aligned at right angle s to a line between the pins.

A checks of the position of the pips will indicate whether or not the lamp has been rotated into the socket correctly. In the conventional tombstone type of socket, the pip or mark should line up with the center of the socket opening.

Gently twist lamps with recessed double contactor bases to assure proper seating. Thoroughly clean dirty sockets. If sockets are loose, adjust or replace them. Replace sockets which are corroded, broken, or show evidence of arcing. Check spacing and alignment of lampholder. If they are too far apart, there may be

poor contact. Adjust them or replace the fixture.

Quick start .Rapid start.

Lack of proper cathode heat.

In a rapid start or quick start system, a lamp which has one or two blackened ends may not be receiving adequate cathode heating. This may be caused by poor contact (above) , by problems within the ballast, by use of ballast which do not deliver minimum lamp requirements, by improper wiring or low-line voltage . Each of these is discussed on the following pages.Various devices are available to test cathode heater voltage. Among these are small lamps mounted in lamp bases. These are go/no-go types of indicators which show only the presence or absences of cathode heat, but which give no indication of quantity. For this reason , they will not necessarily reveal insufficient heat. It is better to use a small voltmeter with a lamp base attachment containing a resistor for a " dummy load " to draw the proper cathode current. With this type of indicator. cathode, heater voltage can be obtained from lamp manufacturers. They are also indicated on most testers. The insertion of a tester into a dirty or corroded socket often scrapes the contact clean enough to obtain a proper reading. Make sure that the contacts are in good condition and that the lamp was sealed as well as the tester. If the tester shows improper cathode voltage, investigate further.

All Normal end of life of lamps.

Cathode coating is exhausted .This is characterized by dense end blackening, extending from the end of the lamp along the lamp wall for 5-8 cm . Lamps may flash for a short period of time or appear to shimmer. Instant start lamps may swirl.The ends of pre-heat lamp may flash on and off. If an arc strikes, it may be characterized by a shimmering effect during the short time it exists.In some two-lamp circuits, particularly series sequence instant start and rapid start circuits, a good lamp may burn at reduced brightness, in a glow state, possibly damaging the cathodes. Also both lamps may be out when only one has failed. Check each individually. Replace failed lamps promptly to avoid ballast damage caused by rectification and overheating. If a good lamp is known to have burn at low brightness for some time, or show indications of being near the end of life, it should also be replaced, since its life may have been significantly reduced because of cathode damage. With any type of circuit the simplest procedure is usually to test lamps in an adjacent fixture which is known to be operating properly and then replace as necessary.

Pre-heat Welded starter contacts or shorted starter capacitor

This is usually indicated bay a lamp glowing at the ends, but not attempting to start . Test starter in an adjacent fixture known to be operating properly and replace if necessary. If the ends of the lamp have been glowing and it starts immediately upon removal of the starter, replace the starter.

Pre-heat Starter at end of Check the starter in an adjacent fixture known to be operating properly, or check the

life circuit with one of the following: A new starter, a starter from a fixture operating normally, a dummy starter can be made from an old starter simply by shorting the pins or leads. It is inserted into the starter socket and removed when the lamp ends begin to glow. This action should be repeated three or four times if necessary. If the lamp has not been starting, but does start on any one of these attempts, the troubles is in the previous starter .Replace it.A manual starter can be made by connecting a hand switch with 300mm or so of wire in series with the two posts in a starter base . It is used in the same manner as the dummy starter except that the switch is opened rather than the base being removed from the socket.

Lamp fail to light

All Ballast not delivering minimum lamp requirements

All ballasts must satisfactorily limit the flow of current in the lamp to a value which is within reasonable limits of the lamp rating. In addition, pre-heat ballasts must provide sufficient pre-heat current and starting voltage; instant start ballast must provide adequate starting voltage and starting current; quick start and rapid start ballast must provide sufficient voltage between lamp terminals, from lamp terminal to starting aid, and proper currents for cathode heat. These values may be obtained from lamp suppliers.To check, use suitable ammeters and voltmeters as directed in AS specifications or lamp or ballast manufacturer's publications. Some simple tests can be made with continuity testers, following the ballast manufacturer's recommendations.Replace ballast. It is highly recommended that approved ballasts be used whenever possible.

Instant start Trigger start Rapid start

High humidity or accumulation of dirt on lamps

Remove , clean and replace the lamps, Use a mild soap solution rather than a detergent which can remove the lamp's silicone coating. If it is advertently removed, the lamps can be wiped with a silicone cloth. It is advisable to let lamps air dry since wiping with a dry cloth may create static electricity which will attract dust.If humid and dusty conditions prevail, it is advisable to enclose the lamps.

All Extreme ambient temperatures (either hot or cold)

Correct ambient, if particle. Otherwise, change to a ballast rated for existing conditions.In conditions of extreme cold, although the lamps do light, their output may be so low that they appear to be unlighted.

All Voltage at fixture too low

Measure with a suitable voltmeter. Correct, or change to a ballast rated for existing supply.

Quick start .Rapid start

Inadequate starting aid

Rapid start and quick start systems require metal starting aids in close proximity to the lamp and running the length of the lamp. This metal must be at earth potential. Usually the fixture reflector serves as the starting aid.Provide suitable starting aid. Requirement can be obtained from the lamp manufacturer.

All Improper wiring Examine the wiring to see that it is in accordance with the diagrams on the ballast label. Ensure that active, neutral and earthing conductors are correctly connected. Check connections to see they are secure. Occasionally, fixtures using the newer type lampholder are found with loose leads - leads which were not properly pushed into the spring clips which are used for wire connections instead of lugs and screws. Leads without the insulation removed has also been found. In some cases, one slot is used for two wires and although there are two spring clips inside the socket, both wires go under one . This can result in a loose connection for one of them.Check the socket arrangement. In some sockets wires from adjacent holes are supposed to be connected to opposite pins while in others they are connected in parallel to the same pin.Make sure there are no short circuit such caused by leads contacting the fixture.There should be nearly full line voltage between the active lead and the metal fixture.Measure voltage across the lamp from the lamp holder on one end to the lampholder on the other ( where only one connection at each end is live being sure to measure the two live ones). Use a voltmeter which has an input impedance of 100 ohms per volt minimum. If there is no voltage or extremely low voltage, measure at succeeding points back toward the power line to determine the location of the problem.In some installations, particularly those using instant starts lamps which require high open circuit voltages, an interlocking type of socket is used for safety . With this type of system the primary ballast circuit is not completed unless a lamp is inserted in the socket. To obtain readings of ballast output it is necessary to complete this circuit.In a pre-heat system, with dummy starter installed, both ends of one lamp should glow. If not, or if in three or four attempts there is no effort to start when the dummy is removed, there could be an open circuit.

If one end of each lamp glows, the wiring is crossed. In each case, check the wiring and correct it in accordance with ballast label.

All Leak in lamp Indicated by absence of fluorescent glow when lamp is exposed to a spark coil. Replace lamp.

Pre-heat, Quick start Rapid start

Open circuit in lamp electrodes

Improper earthing, improper wiring, broken lampholder, or insufficient ballasting, any of which can cause excessively high voltage to be impressed across the cathode, may cause this. Other causes are transportation damage, poor weld, broken coils and lamp with air leaks.Test with continuity tester or by connecting adjacent lamp contacts in series with a test resistance such as a 25-watt incandescent lamp on a 240V line .Another method of inspecting the cathode is to use a simple shadowgraph . This device is readily constructed by making a small hole in a square of cardboard or other opaque material that is held in front of shielded filament lamp. The lamp to be examined is held against the pinhole and a shadow of the cathode will be projected on the side of the lamp opposite the cardboard. By tuning the lamp slowly, the cathode, leads, etc. , can be examined and any breaks, distortions, or missing cathodes will be easy to see. Replace the lamp.

All Short circuit within ballast

If one lamp is out and the other is operating at full brightness in a rapid start series sequence circuit, there is probably a shorted starting capacitor. This can be determining by checking continuity between the leads to the lamp that is out. If any tow leads at opposite ends show continuity, there is a short circuit. Replace the ballast.

All Ballast end of life when the insulation on the ballast windings fails, the ballast will no longer supply lamp requirements and has , therefore , reached the end of its life. Time and temperature affect the life of the insulation. If the ballast is subject to high operating temperatures, case temperatures over 90 deg C, its life will be substantially reduced. General rule of thumb is that each increase of 10 deg C above 90 deg C rating will halve ballast life.Leaking compound , expect for a small amount at the lead holes, which is normal; cracking or brittle insulation; and discoloration on the metal case are all indications of ballast approaching or having reached end of life. The simple fact that a ballast starts a lamp is not a true indication that the ballast is functioning properly. Often many successive lamps appear t have short life in a given fixture before it is realized that the ballast has reached the end of useful life.Check with appropriate continuity testers, ammeters and voltmeters as detail in ballast manufacturers' publications. Replace the ballast.

Slow of erratic starting

All Wrong lamp See appropriate section in "Lamps fail to light"


See appropriate section in "Lamps fail to light"

Quick start Rapid start

Lack of proper cathode heat


Pre-heat Sluggish starter, causing prolonged flashing at each start

Test starter in adjacent fixture known to be operating properly. Replace starter.



All High humidity or accumulation of dirt on lamp


All Extreme ambient temperatures (either hot or cold)


All Voltage at luminaries low or fluctuating

Measure with suitable voltmeter. If fluctuating voltage is suspected, a recording voltmeter will be helpful. Correct supply.


Inadequate starting aid


All Improper wiring See appropriate section in "Lamps fail to light"New lamps fail within the first few days of operation

All Wrong lamps See appropriate section in "Lamps fail to light"

All Wrong ballast Verify that proper ballast is used for the fixture and for existing electrical and environmental conditions. Ballast must be a.c. or d.c., depending on supply characteristics, and must be of correct line voltage and frequency rating . If low temperature conditions exist, a low temperature ballast should be used. Replace with appropriate ballast.

Pre-heat reset-type starter not reset


All Improper wiring See appropriate section in "Lamps fail to light"All Leak in lamp:

may develop so slowly that lamp will operate satisfactory for a short period of time


Pre-heat Quick start Rapid start

Open circuit in lamp electrodes



See appropriate section in " Lamps fail to light" short circuit can occur which cause a lamp to operate at excessive current. To check , follow ballast manufacturers' suggested testing procedures.As a general rule, the following can be done: however, there are some exceptions.Place an ammeter in series with the lamp and if the meter reads more than 120 percent of rated lamp current, replace the ballast. For pre-heat and instant start system place an ammeter in series with the lamp, preferably between the lamp and the ballast secondary lead which is at earth potential. For quick start and rapid start systems do likewise; however, after the lamp is ignited remove the adjacent secondary lead to avoid including cathode heating current in the reading.

Short lamp life All Wrong lamps Although some lamps may operate for a period of time on the wrong type of circuitry, there will nearly always be serious disadvantages to such operation. For example, 800 milliampere (high-output) lamps will operate on 1500 milliampere ballast but with substantial sacrifice in lamp and ballast life, lamp maintenance and efficiency.Operating 1500 milliamperes(VHO) lamps on 800 milliampere ballast can have similar effects reducing ballasts and possibly lamp life and efficiency.

All Normal failures Although rated life is usually many thousand hours, it is by definition the point in time at which 50 percent of the lamps in a statistically large sample have failed. Actually, some lamp will fail before this time and some after . One must expect a small percentage of comparatively early failures.

All Short burning cycle

Rated life of fluorescent lamps is based on an average burning period of three hour per start. If the burning period per start is lengthened, the life of the lamp will increase . On the other hand, if the average burning periods decreased, lamp life will be reduced. Review the operating schedule and the local economics. It is often found that turning off the lamps for the short period of time, to reduce the electrical consumption, actually results in a net increase in installation operating costs because of the adverse effects on lamp life.




Lack of proper cathode heat




All Voltage at fixture too high to too

If the voltage delivered to a pre-heat to rapid start fluorescent luminaries is higher than normal , light output will increase, but the lamp will frequently instant start, that is , start

low without proper cathode preconditioning, causing rapid deterioration of the cathode and resulting in reduced lamp life. Occasionally with preheat circuits, this instant starting can be recognized. The lamps will start without preheating or will sometimes flash, go out and then start normally, that is preheating the cathode and then striking the arc. In additions to its effects on the lamps, a high line voltage can cause the ballast to run at an abnormally high currents, thereby reducing its life. The high current will also decrease the lamp's maintained light output.If the voltage at the luminary is low, light output will be reduced, lamp operation may be unstable, and starting can become slower, more strained or prolonged, which is damaging to the cathodes and decreases lamp life.In either case check line voltage at the luminaries with a standard voltmeter or a recording voltmeter if fluctuating is suspected. Correctly supply as necessary or use a ballast designed for the specific voltage being supplied. Consult ballast manufacturers' recommended practical limits.

All Wrong ballast See appropriate section in "New lamps fail to light within the first few days of operation".Pre-heat Wrong starter Consult starter manufacturers' publication or package and replace with correct starter. A

manual or automatic reset type is advisable for installations where a failed lamp is not replaced within one hour.

Pre-heat Sluggish starter See appropriate section in "Slow or erratic starting"Pre-heat Premature starting The lead lamp in a two-lamp circuit is often prone to start before its cathodes are properly

preheated. Since this characteristic cannot often be visually recognized, whenever the lead lamps have shorter life than the lag, it is advisable to use a starter designed to reduce this effect.

Series sequence

Lamp operating in the glow state

When one lamp in a two -lamp series sequence circuit has failed, the other may burn at reduced brightness, in a glow state. This may damage the cathode of the good lamp and reduce its life. Replace failed lamps promptly. If a lamp that has burned in the glow state exhibits signs of being near the end of life (see "Normal end of life of lamps") it is a good idea to replace it at the same time the failed lamp is being replaced.

All Improper wiring See appropriate section in "Lamps fail to light"All Open circuit in

lamp electrodesSee appropriate section in "Lamps fail to light"



Snaking blinking or flickering

All Impurities At the arc in a fluorescent lamp may swirl and twist within the lamp. This usually occurs in a new lamp and will disappear when the lamp has been operated a few days or turned on and off a few times one half hour or more apart. Occasionally, this "sneaking" may occur in a lamp during normal operation. Turning the lamp off and on usually remedies this. If not, replace the lamp. If other lamps in the same luminaries also swirl, investigate further.

All Normal stroboscopic effect due to alternating current

Although this is not often a problem with the holding properties of today's phosphors, it can be reduced by using the warm colors, which have the slowest rate of decay, by operating on lead-lag circuit or by operating on three-phase power supplies.



All Normal end of life of lamps


All Low lamp wall temperature

Low lamp wall temperature caused by draughts from outside air, air-conditioning, etc. can cause flickering or blinking. Protect or enclose the lamp.

All Wrong ballast If the ballast frequency rating is not the same as the line frequency, flickering may occur. Replace with ballast of proper rating.

Pre-heat Wrong starter Remove the starter while the lamp is lighted. If the flashing stops, the starter is the wrong size, or is defective. Replace it.

Pre-heat Sluggish starter See appropriate section in "Slow or erratic starting"Pre-heat Starter not

cycling correctly to proper preheats electrodes.

Characterized by rapid blinking of lamp ends. Test starter in adjacent circuit and replace.

All Ballast not delivering minimum load requirements


All Voltage at luminaries too high or too low

Measure with suitable voltmeter and correct. See appropriate section in "Lamps fail to light"

All Improper wiring See appropriate section in "Lamps fail to light"All Open circuit in

lamp electrodeSee appropriate section in "Lamps fail to light"

PLC MAINTENANCE, TROUBLESHOOTING

CONSIDERATION OF THE OPERATING ENVIRONMENT The PLC installed in an enclosure, NEMA type metal enclosure. NEMA type enclosure must be planned to allow adequate

room for incoming control wires & power wiring and easy access to all parts and wires for installation, future alterations, and troubleshooting.

Temperature of operating limit ( upper & lower ), normally 0 degC (32degF) and 60 degC ( 140 degF ) Moisture, Dust, and Corrosive Atmosphere: - It may operate in High Humidity.

- Level of moisture - Dust - Corrosive Atmosphere (Chemical plant, refineries) where oxidizing fumes may be present, electrical connection can fail to buildup of oxides on the wires and terminals.

Vibration - excessive vibration ( transmitted from nearby vibrating equipment ) can effect to PLC malfunction . It can be reduced by shock-prevention mountings.

RECEIVING CHECK, TESTING AND ASSEMBLY Receiving - When receive the PLC system from manufacturer, inspect the packing boxes for any

Obvious damage. Checking - If it is damage, take a picture of them before opening

- In case the parts inside the packages may also be damage.- Check out the inventory that is it same the parts and manual received against the packing list provided.- Review, record & sort out the purchase order and listing of parts which you received- Many electronic parts and assemblies are easily to damage by small charge of static electricity, therefore manufacturers normally provide anti-static bags for normal shipment. - Before remove that bags, check it out that it's damage and record, return them to supplier for replacement or recheck. So when it is removed, it may need special handling like static free environment.- If the modules are installed into the system, the same precaution is necessary.- Portable grounding kits are available from some manufacturers to prevent static damage of parts during handling.

Testing - After complete assembled, PLC is ready for testing.- First PLC tested "as is," without attaching any wiring to the I/O modules.- Electrical jumpers moved around from input to input to check for correct operation.

* Output program energized indicating light is correct not.* FORCE mode (use keyboard) may convenient to check for correct input operation than moving jumpers around as input simulation method. The disadvantage is that it cannot check to input module operation.* MONITOR mode can observe the ladder program operation on the PLC screen, which gives a better view of the PLC internal operation.

- Second, tested with simulator. (Discrete simulator, Analog simulator)* A switch is attached for each input, and indicating lights attached for each output

- Third, tested after it is hooked up to the system to operate.* Direct connects to the PLC with the factory operation system it is to control.

Disadvantage :- If the PLC is malfunction, the equipment being used for testing can bedamaged. The operator or programmer error can cause sequence problem oreven damage to equipment. Personnel injured during PLC malfunction.

- Above all testing method use in FROCE mode for proper operation bykeyboard (input, output ), this override the system's normal operation through the input module. FORCE mode could be dangerous to equipment or personnel.

- Testing to peripheral (printers, disk drives and tape drives) also takes special testing procedure. e.g. a printer can print five different type of information, all five modes of operation should be tested.- A complete test of the PLC system and CPU involves checking every function; each input and output

should be checked, for every function (TIMER, COUNTER, MASTER CONTROL RELAY etc.). Even if it is not to be used initially, check every function for recovery to warranty period.

INSTALLATION, ELECTRICAL CONNECTION, GROUNDING, AND SUPPRESSION Initial facts & Battery - Practically all PLCs have backup battery systems. Some system use a

common 1.5V or 9V long life battery or various type of batteries with special voltage ratings or rechargeable battery that is trickle-charged by a small power supply in the CPU.

- Separately shipped batteries are installed according to manufacturer's instructions. - Special precaution during installation might include removal of some modules of wires to prevent static damage or electrical surges to some parts of CPU. - In all cases, battery voltage should be checked for compliance to voltage specifications listed in the PLC manual before installation. - All PLC systems have at least one fuse; many have a number of different fuses. These may be in place when the PLC is shipped. If not, the fuses must be installed according to startup instruction in the manual.

CPU - Plug in the line cord to CPU & all parts.- Check the CPU for proper operation as turn the key-switch or master switch from position to

position and check to see that all operating pilot lights come on at the proper time. If it not, internal visual checks are in order (the faceplate or an appropriate panel may be removed). Then check for any loose connection.

Input & Output Modules - Assembly of input and output modules are larger units in the racks which are not only mechanical supports but also have interconnecting electrical wires and connections so take care that modules are put precisely in place.- Modules are next connected to the CPU with the proper cables, care must be taken that the connecting ribbon cables are not too twisted or pull during installation. - Next, the wires from the external devices and switches are attached to the I/O terminals. The standard practice of "hand tight" is normally followed. - Peripheral devices such as printers, disk drives, and tape drives may now be interconnected to the system by means of their cables.- Remote station and buses to the other PLCs and computers should not be connected until the individual PLC checkout is complete.

Grounding - Proper grounding of wiring of the equipment and cabinet is essential for personnel safety and assure proper equipment operation.- Ungrounded or improperly grounded wire or part could become shorted electrically to metal cabinet or rack, presenting to electrical harzard to users.- PLC is computer based and computers need a proper and solid grounding system for consistently trouble-free operation.

Suppression - Electrical disturbance from devices outside the PLC system can cause program operation malfunction.- Electrically inductive nature (Solenoids, starter coils, motors & other devices) cause an electrical pulse to be back fed and PLC in mistake and PLC sequence flow in malfunction.- Standard copper outer sheath around shield cable prevent above disturbance.

- Suppressors can absorb above false pulse which passed through external prevention technique and it get no disturbance signal send to PLC.

- Master control relay system can be provided to override the whole PLC operation to shut down for safety precaution.

Circuit Protection & Wiring

ProtectionSome major considerations in choosing fuse are

1. Rated current for melting or blow2. Rated current of PLC3. Interrupt capability. ( A 20A fuse will not stop 20,000 amps. The current will arc over.)4. Temperature of the environment in which the fuse will operate. (Higher temperature means

faster action and blowing below rated value.)5. Type of mounting6. Replaceable link or one-time operation7. Time delay or regular-do not use time delay fuses for PLCs; use regular fuses.8. Other special requirements9. Consult with fuse specialist10. Circuit Breaker can reset quickly and do not need to be replaced, but fuse blown faster can give

more protection to PLC11. Overload protection is accomplished by internal, specially calibrated overload relays in PLC

itself ( so it need to reset only)12. Wire size must be large enough to prevent line loss, drawn by PLC, it cause voltage drop due to

feeder wire's resistance and PLC can cause erratic PLC operation.13. It is best to connect PLC and other electronic equipment to separate power feeder lines (to avoid

disturbance).14. Electronic equipment & PLC can be affected by power wave form distortion, which caused by

following:-14.1. Surge form lightning hitting power lines14.2. Disturbances from adjacent building or factories14.3. Surges from switching action by the power company or in your plant.14.4. Internal factory power waveform disturbances.

15. Above distortion can correct by line purifier unit, it can not only waveform purify but also maintain proper stabilization in line voltage. Also it can perform as battery standby unit as UPS.

Troubleshooting PLC Malfunction1. Take care safety precaution ( process, power turn on/off, wear glass, insulated handtools, work deliberately, consider the

consequences of each step )2. Must understanding that what is malfunction? document problem in detail including the date, time, severity and

circumstances of malfunction. 3. Check for replace any blown fuses.4. Visual inspection.5. Is power to all control ckt?6. Are there broken wires?7. Are switches set in proper position?8. Have any undocumented alteration to parts been made?9. Review of terminal wiring diagrams may reveal that an unrecorded change is causing the trouble.10. Establish that the system malfunction is not caused by an external part or system then check the PLC itself for proper

operation in each applicable mode.11. Larger PLCs have an available screen readout for CPU status, call up status and refer to operating manual to state it.12. Any portion not meeting the normal shows an operational area, in some cases just clearing the CPU memory and

reprogramming to eliminate PLC malfunction.13. If it has another CPU available, replace the one in service with it, and reprogram the old CPU was using. If problem is

corrected, old CPU could be culprit. If it is same problem that it is no problem in CPU and analyzes subparts by substitution in similar manner.

14. Use MONITOR mode is helpful troubleshooting, by observing the program ladder operation on the screen.15. FORCE mode is useful in simulating operating conditions. Caution that it is not during actual operation condition.16. Many PLCs have available a fault indication register display on screen, it may internal fault condition or external fault

condition. Therefore follow up fault register to get correction the problem.17. PLC malfunctions correct by replace printed circuit board or single electronic component.18. After replacing finished, it still has problem. Following may happens

18.1. Replacement parts also faulty.18.2. Another part or parts in the PLC are faulty. Further analysis need.18.3. Overload cause in the system affect. or severely damage in other portion of

system, so it need to quick pre-check before expansive parts to replace. ( supply voltage must correct )

19. Written log of failures correction for each PLC should be kept. If failure in second time, reviewing the log will enable the troubleshooter to benefit. The log should include a description of failure and corrective action taken, as well as the date and shift of occurrence.

20. More spare parts for a particular failure mode may have to keep on hand.

PLC Maintenance1. Periodically check the tightness of I/O module terminal screws. They can become loose over a period of time.2. Periodically check the corrosion of connecting terminals. Moisture and corrosive atmospheres can cause poor electrical

connections. Internally end connectors of PCB also may become corroded.3. Make sure that components are free of dust. Properly cooling the PLC through a layer of dust is impossible.4. Stock commonly needed spare parts. Input and output modules are the PLC components that fail most often. Stocking is

especially essential there is no convenient manufacturer's service station and part depot. Maintaining proper levels of spare parts inventory is a trade-off between costly inventory and prolonged downtime without parts.

5. Keep a duplicate record of operating programs being used. These records should be kept the plant location away from the PLC operational area. Copies of long expensive programs should be kept off the premises to prevent their loss in case of fire and theft.

6. Replace the PLC backup batteries more often than their usable life would indicate. The lithium batteries used for backup in case of lost electrical service are usable for 3-5 years. However, many companies replace them on the yearly on a written maintenance procedure. The cost of the batteries small price to pay to prevent the loss of lengthily PLC program.

7. Have a written checklist control sheet for each PLC. The sheet should have the dates on which the work is performed and the dates for the next preventative maintenance due. The next due dates should be entered on a future worksheet listing to make sure it is done on the date due.

8. Keep a log sheet on maintenance for each PLC in addition to the check-sheet. Records of what, who, and when should be kept. This log is often combined with the troubleshooting log discussed in the previous section. The combined log sheet gives a valuable history record and is a guide to buying future PLCs based on performance or nonperformance.

This is typical drawing for Forward Reverse motor control unit in United Cement Project (Singapore). There are 2-type control, first direct electrical power control by local control selector switch and second automatic PLC computerize control by Siemen (Germany) technology.

Above typical Drawing is Star Delta starter and automatic PLC computerizes control. unit in United Cement Project (Singapore).There are 2-type control, first direct electrical power control by local control selector switch and second automatic PLC computerize control by Simen(Germany) technology.

Above circuit is typical AutoTransformer starter circuit which is useful to control motor starting current by voltage transition, and which is in two-type first open transition and second close transition.

ILLUMINATION DESIGN TABLEIncandescent Lamps

Room Index

Utilization Factor New Conditions Maintenance Factor

Type of fitting v % k rc 0.7 0.5 0.3 Clean Clean Cleanrw 0.5 0.3 0.1 0.5 0.3 0.1 0.5 0.3 0.1 Once once once

Direct 1 0.27 0.21 0.17 0.26 0.21 0.17 0.26 0.21 0.17 Yearly every every1.2 0.32 0.26 0.21 0.31 0.25 0.21 0.3 0.25 0.21 2 Years 3 Years1.5 0.38 0.32 0.27 0.37 0.32 0.27 0.36 0.31 0.27

2 0.46 0.4 0.36 0.45 0.4 0.36 0.44 0.39 0.360 2.5 0.51 0.46 0.42 0.5 0.46 0.42 0.49 0.45 0.42 Soiling

rate low

| 3 0.55 0.5 0.46 0.54 0.5 0.46 0.53 0.46 0.4680 4 0.61 0.56 0.53 0.6 0.56 0.53 0.59 0.55 0.53 Soiling

rate normal

| 5 0.64 0.6 0.57 0.63 0.6 0.57 0.62 0.6 0.57 1.35 1.5580 6 0.67 0.63 0.61 0.66 0.63 0.6 0.65 0.62 0.6

8 0.7 0.67 0.65 0.69 0.67 0.65 0.68 0.66 0.65 Soiling rate

high10 0.72 0.7 0.68 0.71 0.69 0.67 0.71 0.69 0.67 1.65 2.15

Fitting at center of room 1 0.29 0.23 0.19 0.28 0.23 0.19 0.28 0.23 0.19

1.2 0.35 0.29 0.25 0.34 0.29 0.25 0.33 0.28 0.251.5 0.42 0.37 0.33 0.41 0.36 0.33 0.41 0.36 0.33

2 0.52 0.47 0.44 0.51 0.47 0.44 0.5 0.47 0.44

SEMI DIRECT 1 0.27 0.21 0.17 0.25 0.2 0.16 0.23 0.19 0.15

1.2 0.32 0.26 0.21 0.3 0.24 0.2 0.27 0.23 0.191.5 0.38 0.32 0.27 0.35 0.3 0.26 0.33 0.28 0.24

2 0.46 0.4 0.35 0.43 0.37 0.33 0.39 0.35 0.322.5 0.51 0.45 0.41 0.47 0.43 0.39 0.44 0.4 0.36 Soiling

rate for low

20 3 0.55 0.5 0.45 0.51 0.47 0.43 0.47 0.44 0.4 1.25 1.4| 4 0.6 0.56 0.52 0.56 0.52 0.49 0.52 0.49 0.46

88 5 0.64 0.6 0.56 0.6 0.56 0.53 0.56 0.53 0.5 Soiling

rate normal

| 6 0.66 0.63 0.59 0.62 0.59 0.56 0.58 0.56 0.53 1.45 1.868 8 0.7 0.67 0.64 0.66 0.63 0.61 0.61 0.59 0.57 Soiling

rate high

10 0.72 0.69 0.67 0.68 0.65 0.63 0.64 0.62 0.6 Fitting at Room Center

1 0.29 0.23 0.19 0.27 0.22 0.18 0.25 0.2 0.171.2 0.34 0.28 0.24 0.32 0.27 0.23 0.3 0.25 0.221.5 0.41 0.36 0.31 0.39 0.34 0.3 0.36 0.32 0.28

2 0.51 0.46 0.42 0.48 0.43 0.4 0.45 0.41 0.38

DIRECT 1 0.27 0.21 0.17 0.23 0.19 0.15 0.2 0.16 0.13 INDIRECT 1.2 0.31 0.25 0.21 0.27 0.22 0.19 0.23 0.19 0.17

1.5 0.37 0.31 0.27 0.32 0.27 0.24 0.8 0.24 0.212 0.44 0.39 0.35 0.39 0.34 0.31 0.33 0.3 0.27

2.5 0.49 0.44 0.4 0.43 0.39 0.36 0.32 0.34 0.31 Soiling rate low

41 3 0.53 0.48 0.44 0.47 0.43 0.39 0.4 0.37 0.35 1.25 1.4| 4 0.58 0.54 0.5 0.51 0.48 0.45 0.44 0.42 0.39

90 5 0.62 0.58 0.55 0.54 0.51 0.49 0.47 0.45 0.43 Soiling rate

normal| 6 0.64 0.61 0.58 0.56 0.54 0.51 0.49 0.47 0.45 1.45 1.8

49 8 0.67 0.64 0.62 0.59 0.57 0.55 0.52 0.5 0.49 Soiling rate

high10 0.69 0.67 0.65 0.61 0.59 0.58 0.53 0.52 0.51

1 0.28 0.22 0.19 0.25 0.2 0.17 0.21 0.18 0.151.2 0.33 0.27 0.23 0.29 0.24 0.21 0.25 0.22 0.191.5 0.39 0.34 0.3 0.35 0.3 0.27 0.3 0.27 0.24

2 0.48 0.43 0.39 0.42 0.39 0.35 0.37 0.34 0.32

Fluorescent Lamps

Utilization Factor New Conditions Maintenance Factor

Type of fitting v % k rc 0.7 0.5 0.3 Clean Clean Clean

rw 0.5 0.3 0.1 0.5 0.3 0.1 0.5 0.3 0.1 Once once onceFluorescent 1 0.27 0.2 0.16 0.24 0.18 0.15 0.21 0.16 0.13 Yearly every every

lamp on 1.2 0.31 0.25 0.2 0.28 0.22 0.18 0.25 0.2 0.16 2 Years 3 Yearsmounting rail 1.5 0.37 0.31 0.26 0.33 0.28 0.12 0.29 0.25 0.21

2 0.45 0.39 0.34 0.4 0.35 0.31 0.35 0.31 0.282.5 0.5 0.44 0.39 0.45 0.4 0.36 0.4 0.36 0.32 Soiling rate

low 33 3 0.54 0.48 0.44 0.48 0.44 0.4 0.43 0.39 0.36 1.25 1.4 1.55| 4 0.6 0.55 0.5 0.54 0.5 0.46 0.48 0.44 0.41 Soiling rate

normal93 5 0.63 0.59 0.55 0.57 0.53 0.5 0.51 0.48 0.45 1.45 1.8 2.05| 6 0.66 0.62 0.59 0.6 0.56 0.53 0.53 0.51 0.48 Soiling rate

high 60 8 0.7 0.66 0.63 0.63 0.6 0.58 0.57 0.54 0.52


1 0.28 0.22 0.17 0.25 0.2 0.16 0.22 0.18 0.141.2 0.33 0.27 0.22 0.29 0.24 0.2 0.26 0.22 0.181.5 0.4 0.34 0.29 0.36 0.3 0.27 0.32 0.28 0.24

2 0.49 0.43 0.38 0.44 0.39 0.35 0.39 0.36 0.32

DIRECT 1 0.29 0.24 0.2 0.29 0.23 0.2 0.28 0.23 0.2Through fitting 1.2 0.35 0.29 0.25 0.34 0.28 0.25 0.33 0.28 0.24

with fluorescent 1.5 0.41 0.36 0.31 0.41 0.35 0.31 0.4 0.35 0.31lamps 2 0.5 0.45 0.41 0.49 0.44 0.41 0.48 0.44 0.41

2.5 0.55 0.5 0.47 0.54 0.5 0.46 0.53 0.5 0.46 Soiling rate low

0 3 0.59 0.55 0.51 0.58 0.54 0.51 0.58 0.54 0.51 X X X| 4 0.65 0.61 0.58 0.64 0.6 0.56 0.65 0.6 0.57

82 5 0.68 0.65 0.62 0.67 0.64 0.62 0.66 0.64 0.62 Soiling rate normal

| 6 0.7 0.67 0.65 0.69 0.67 0.65 0.69 0.67 0.65 1.4 1.7 1.982 8 0.73 0.71 0.69 0.72 0.71 0.69 0.7 0.7 0.69 Soiling rate

high 10 0.75 0.73 0.71 0.74 0.73 0.71 0.74 0.72 0.71 1.85 2.55 3.1

Fitting at Room Center 1 0.32 0.26 0.22 0.31 0.26 0.22 0.3 0.26 0.22

1.2 0.38 0.33 0.29 0.37 0.32 0.29 0.37 0.32 0.291.5 0.46 0.41 0.38 0.46 0.41 0.38 0.45 0.41 0.38

2 0.57 0.53 0.5 0.57 0.53 0.5 0.56 0.53 0.5

DIRECT 1 0.25 0.2 0.17 0.22 0.18 0.15 0.19 0.15 0.13 INIRECT 1.2 0.3 0.24 0.21 0.26 0.21 0.18 0.22 0.18 0.13

with louver 1.5 0.35 0.3 0.26 0.3 0.26 0.23 0.26 0.23 0.22 0.42 0.37 0.33 0.36 0.33 0.29 0.31 0.28 0.26

2.5 0.47 0.42 0.38 0.4 0.37 0.34 0.34 0.32 0.29 Soiling rate low 43 3 0.5 0.46 0.42 0.43 0.4 0.37 0.37 0.34 0.32 1.35 1.55 1.75| 4 0.55 0.51 0.48 0.47 0.44 0.42 0.4 0.38 0.36 Soiling rate

normal85 5 0.58 0.54 0.51 0.5 0.47 0.45 0.43 0.41 0.39 1.65 2.15 2.5| 6 0.6 0.57 0.54 0.52 0.5 0.48 0.44 0.43 0.41 Soiling rate

high 42 8 0.62 0.6 0.58 0.54 0.53 0.51 0.47 0.45 0.44 X X X

10 0.64 0.68 0.6 0.56 0.54 0.53 0.48 0.47 0.46Fitting at Room Center

1 0.27 0.22 0.18 0.23 0.19 0.16 0.2 0.17 0.141.2 0.31 0.26 0.23 0.27 0.23 0.2 0.24 0.2 0.181.5 0.38 0.33 0.29 0.33 0.29 0.26 0.28 0.25 0.23

2 0.45 0.41 0.37 0.4 0.38 0.34 0.34 0.32 0.3

SEMI- 1 0.24 0.19 0.15 0.2 0.16 0.13 0.16 0.13 0.11 INDIRECT 1.2 0.28 0.23 0.19 0.23 0.19 0.16 0.19 0.16 0.13

with louver 1.5 0.33 0.28 0.24 0.28 0.23 0.2 0.22 0.19 0.172 0.4 0.35 0.31 0.33 0.29 0.26 0.27 0.24 0.22

2.5 0.44 0.39 0.35 0.37 0.33 0.3 0.3 0.27 0.25 Soiling rate low

51 3 0.47 0.43 0.39 0.4 0.36 0.33 0.32 0.3 0.8 1.4 1.65 1.85| 4 0.52 0.48 0.45 0.44 0.41 0.38 0.36 0.33 0.31 Soiling

rate normal85 5 0.55 0.51 0.48 0.46 0.44 0.41 0.38 0.36 0.34 1.7 2.25 2.65| 6 0.57 0.54 0.51 0.48 0.46 0.44 0.39 0.38 0.36 Soiling

rate high34 8 0.6 0.57 0.55 0.51 0.49 0.47 0.41 0.4 0.39 X X X


1 0.25 0.2 0.16 0.21 0.17 0.14 0.17 0.14 0.121.2 0.29 0.24 0.2 0.25 0.21 0.18 0.2 0.17 0.151.5 0.35 0.3 0.26 0.29 0.25 0.23 0.24 0.21 0.19

2 0.42 0.37 0.34 0.35 0.32 0.29 0.29 0.27 0.25

INDIRECT 1 0.12 0.1 0.08 0.08 0.06 0.05 0.04 0.04 0.03Recess with 1.2 0.14 0.11 0.09 0.09 0.07 0.06 0.05 0.04 0.04

Fluorescent lamps 1.5 0.17 0.13 0.12 0.11 0.09 0.08 0.06 0.05 0.042 0.2 0.17 0.15 0.13 0.11 0.1 0.07 0.06 0.06

2.5 0.21 0.2 0.17 0.14 0.13 0.12 0.08 0.07 0.07 Soiling rate low

70 3 0.23 0.21 0.18 0.15 0.14 0.12 0.08 0.08 0.07 1.25 1.45 X| 4 0.25 0.23 0.21 0.17 0.15 0.14 0.09 0.09 0.08 Soiling rate

normal70 5 0.27 0.25 0.23 0.18 0.16 0.15 0.1 0.09 0.09 X X X| 6 0.28 0.26 0.24 0.18 0.17 0.16 0.1 0.1 0.09 Soiling rate

normal

0 8 0.29 0.27 0.25 0.19 0.18 0.17 0.11 0.1 0.1 X X X10 0.31 0.28 0.27 0.2 0.19 0.18 0.11 0.11 0.1

SELECTION OF MOTOR STARTER & FUSE FREE BREAKER

DIRECT ON LINE STARTER ( DOL starter )1. The method of motor starting is direct on line under AC3 operating conditions according to IEC 158-1.2. The motor is Hitachi standard type squirrel cage 4 pole induction motor.3. The heater range for the thermal overload relays are selected from the motor's full load current.4. The selection of FFB is on the basis of 600% current for 10 sec.

DOL Starter in rated 220V 3 Phase 50HzRating

_HPRating

_KWFull_Load

Type_of_Magnet_Starter Thermal_OL Heater_Range(A)

NH_Fuse

(A)

Type_S_Series

Type_F_Series Rated_Curren

t(A)

Wire_Size(sq-mm)

0.13 0.1 0.78 K10NEP2_or_K11NEP2 TR11-1E 0.6-1.0 4 S-305 F-50K_or_F-50F 3 10.27 0.2 1.3 K10NEP2_or_K11NEP2 TR11-1E 0.8-1.6 6 S-305 F-50K_or_F-50F 3 10.33 0.25 1.2 K10NEP2_or_K11NEP2 TR11-1E 0.8-1.6 6 S-305 F-50K_or_F-50F 3 1

0.5 0.4 1.7 K10NEP2_or_K11NEP2 TR11-1E 1.6-3.2 10 S-305 F-50K_or_F-50F 5 10.75 0.55 2.3 K10NEP2_or_K11NEP2 TR11-1E 1.6-3.2 10 S-305 F-50K_or_F-50F 5 1

1 0.75 2.9 K10NEP2_or_K11NEP2 TR11-1E 2.5-5.0 10 S-305 F-50K_or_F-50F 8 11.5 1.1 4.2 K10NEP2_or_K11NEP2 TR11-1E 2.5-5.0 10 S-305 F-50K_or_F-50F 8 1

2 1.5 5.8 K10NEP2_or_K11NEP2 TR11-1E 4.5-9.0 16 S-305 F-50K_or_F-50F 15 13 2.2 7.8 K10NEP2_or_K11NEP2 TR11-1E 6-12 20 S-305 F-50K_or_F-50F 20 1.54 3 10.5 K15CNEP3_or_K15BNEP

3TR20-1E 6-12 25 S-305 F-50K_or_F-50F 20 1.5

5 3.7 13 K15CNEP3_or_K15BNEP3

TR20-1E 12-18 35 S-305 F-50K_or_F-50F 30 1.5

5.5 4 14 K15CNEP3_or_K15BNEP3

TR20-1E 12-18 35 S-305 F-50K_or_F-50F 30 1.5

7.5 5.5 20 K15CNEP3_or_K15BNEP3

TR20-1E 16-24 50 S-50 F-50K_or_F-50F 50 4

10 7.5 25 K20BNEP3 TR40-1E 22-34 63 S-50 F-50K_or_F-50F 50 415 11 36 K25BNEP3 TR40-1E 32-48 80 S-100S F-100G 75 1020 15 50 K30BNEP3 TR40-1E 45-65 100 S-100S F-100G 100 1025 18.5 62 K50N-EP3 TR100-1E 45-65 125 S-100S F-100G 100 1630 22 72 K60N-EP3 TR100-1E 55-80 160 S-225S F-225F_or_F-225KB 150 2540 30 100 K100N-EP3 TR100-1E 90-120 200 S-225S F-225F_or_F-225KB 200 3550 37 120 K120N-EP3 TR100-1E 110-150 250 S-225S F-225F_or_F-225KB 225 5060 45 145 K150N-EP3 TR100-1E 110-150 250 S-225S F-225F_or_F-225KB 225 7075 55 180 K200N-EP3 TR20E-1

_with_CT100N1.6-3.2 400 S-400S F-400F 350 95

100 75 240 K250N-EP3 TR20E-1 _with_CT100N

1.6-3.2 500 S-600S F-600F 500 120

125 90 290 K300N-EP3 TR20E-1 _with_CT100N

2.5-5 800 S-600S F-600F 600 185

150 110 350 K400N-EP3 TR20E-1 _with_CT100N

2.5-5 800 S-800S F-800K 700 240

180 132 410 K600N-EP3 TR20E-1 _with_CT100N

2.5-5 800 S-800S F-800K 800 240

220 160 520 K600N-EP3 TR20E-1 _with_CT100N

4.5-9 800 N.A U-800 800 240

270 200 N.A N.A N.A N.A N.A340 250 N.A N.A N.A N.A N.A

DOL Starter in rated 380V 3 Phase 50HzRating

_HPRating

_KWFull_Load

Type_of_Magnet_Starter Thermal_OL Heater_Range(A)

NH_Fuse (A)

Type_S_Series

Type_F_Series Rated_Current (A)

Wire_Size

(sq-mm

0.13 0.1 0.42 K10NEP2_or_K11NEP2 TR11-1E 0.35-0.65 4 S-30SZ F-50K_or_F-50F 3 10.27 0.2 0.64 K10NEP2_or_K11NEP2 TR11-1E 0.6-1.0 4 S-30SZ F-50K_or_F-50F 3 10.33 0.25 0.7 K10NEP2_or_K11NEP2 TR11-1E 0.6-1.0 4 S-30SZ F-50K_or_F-50F 3 1

0.5 0.4 1 K10NEP2_or_K11NEP2 TR11-1E 0.8-1.6 6 S-30SZ F-50K_or_F-50F 3 10.75 0.55 1.3 K10NEP2_or_K11NEP2 TR11-1E 0.8-1.6 6 S-30SZ F-50K_or_F-50F 3 1

1 0.75 1.7 K10NEP2_or_K11NEP2 TR11-1E 1.6-3.2 6 S-30SZ F-50K_or_F-50F 3 11.5 1.1 2.4 K10NEP2_or_K11NEP2 TR11-1E 1.6-3.2 8 S-30SZ F-50K_or_F-50F 5 1

2 1.5 3.3 K10NEP2_or_K11NEP2 TR11-1E 2.5-5.0 10 S-30SZ F-50K_or_F-50F 5 13 2.2 4.5 K10NEP2_or_K11NEP2 TR11-1E 2.5-5.0 10 S-30SZ F-50K_or_F-50F 8 14 3 6.2 K10NEP2_or_K11NEP2 TR11-1E 4.5-9.0 16 S-30SZ F-50K_or_F-50F 15 15 3.7 7.5 K10NEP2_or_K11NEP2 TR11-1E 4.5-9.0 20 S-30SZ F-50K_or_F-50F 20 1.5

5.5 4 8.5 K15CNEP3_or_K15BNEP3 TR20-1E 6-12 20 S-30SZ F-50K_or_F-50F 20 1.57.5 5.5 11.5 K15CNEP3_or_K15BNEP3 TR20-1E 6-12 35 S-30SZ F-50K_or_F-50F 30 1.510 7.5 14.5 K15CNEP3_or_K15BNEP3 TR40-1E 12-18 35 S-30SZ F-50K_or_F-50F 30 1.515 11 21 K20BNEP3 TR20-1E 16-24 50 S-50S F-50K_or_F-50F 50 420 15 29 K25BNEP3 TR40-1E 22-34 63 S-50S F-50K_or_F-50F 50 625 18.5 36 K30BN-EP3 TR40-1E 32-48 80 S-100S F-100G 75 1030 22 42 K30BN-EP3 TR40-1E 32-48 80 S-100S F-100G 75 1040 30 55 K50N-EP3 TR100-1E 45-65 100 S-100S F-100G 100 16

50 37 68 K60N-EP3 TR100-1E 55-80 160 S-225S F-225F_or_F-225KB

150 25


150 25

75 55 105 K120N-EP3 TR100-1E 90-120 200 S-225S F-225F_or_F-225KG

175 35

100 75 140 K150N-EP3 TR100-1E 110-150 250 S-225S F-225F_or_F-225KG

225 50

125 90 165 K200N-EP3 TR20E-1_with_CT100

N

1.0-1.8 315 S-225S F-225F_or_F-225KG

225 70

150 110 200 K250N-EP3 TR20E-1_with_CT100

N

1.6-3.2 400 S-400S F-400F 350 95

180 132 230 K300N-EP3 TR20E-1_with_CT100

N

1.6-3.2 500 S-600S F-600F 500 120

220 160 300 K400N-EP3 TR20E-1_with_CT100

N

2.5-5 800 S-600S F-600F 500 185

270 200 370 K400N-EP3TR20E-1_with_CT100N

2.5-5 800 S-800S

F-800K 700 240

340 250 475 K600N-EP3TR20E-1_with_CT100N

2.5-5 800 S-800S

F-800K 800 240

DOL Starter in rated 415V 3 Phase 50HzRating_

HPRating_

KWFull_Load Type_of_Magnet_Starter Thermal_OL Heater_

Range(A)NH_Fuse (A)

Type_S_Series

Type_F_Series Rated_Curren

t (A)

Wire_Size (sq-mm

0.13 0.1 0.34 K10NEP2_or_K11NEP2 TR11-1E 0.2-0.4 4 S-30SZ F-50K_or_F-50F 3 10.27 0.2 0.63 K10NEP2_or_K11NEP2 TR11-1E 0.6-1.0 4 S-30SZ F-50K_or_F-50F 3 10.33 0.25 0.7 K10NEP2_or_K11NEP2 TR11-1E 0.6-1.0 4 S-30SZ F-50K_or_F-50F 3 1

0.5 0.4 1 K10NEP2_or_K11NEP2 TR11-1E 0.8-1.6 6 S-30SZ F-50K_or_F-50F 3 10.75 0.55 1.3 K10NEP2_or_K11NEP2 TR11-1E 0.8-1.6 6 S-30SZ F-50K_or_F-50F 3 1

1 0.75 1.7 K10NEP2_or_K11NEP2 TR11-1E 1.6-3.2 6 S-30SZ F-50K_or_F-50F 3 11.5 1.1 2.5 K10NEP2_or_K11NEP2 TR11-1E 1.6-3.2 8 S-30SZ F-50K_or_F-50F 5 1

2 1.5 3.4 K10NEP2_or_K11NEP2 TR11-1E 2.5-5.0 10 S-30SZ F-50K_or_F-50F 5 13 2.2 4.5 K10NEP2_or_K11NEP2 TR11-1E 2.5-5.0 10 S-30SZ F-50K_or_F-50F 8 14 3 5.8 K10NEP2_or_K11NEP2 TR11-1E 4.5-9.0 16 S-30SZ F-50K_or_F-50F 15 15 3.7 7.2 K10NEP2_or_K11NEP2 TR11-1E 4.5-9.0 20 S-30SZ F-50K_or_F-50F 20 1.5

5.5 4 8.5 K15CNEP3_or_K15BNEP3 TR20-1E 6-12 20 S-30SZ F-50K_or_F-50F 20 1.57.5 5.5 11.5 K15CNEP3_or_K15BNEP3 TR20-1E 6-12 35 S-30SZ F-50K_or_F-50F 30 1.510 7.5 14 K15CNEP3_or_K15BNEP3 TR20-1E 12-18 35 S-30SZ F-50K_or_F-50F 30 1.515 11 21 K20BNEP3 TR20-1E 16-24 50 S-50S F-50K_or_F-50F 50 420 15 28 K25BNEP3 TR40-1E 22-34 63 S-50S F-50K_or_F-50F 50 625 18.5 35 K30BN-EP3 TR40-1E 32-48 80 S-100S F-100G 75 1030 22 40 K30BN-EP3 TR40-1E 32-48 80 S-100S F-100G 75 1040 30 52 K50N-EP3 TR100-1E 45-65 100 S-100S F-100G 100 1650 37 62 K60N-EP3 TR100-1E 55-80 160 S-225S F-100G 100 1660 45 80 K100N-EP3 TR100-1E 65-95 160 S-225S F-225F_or_F-

225KB150 25


175 35


225 50

125 90 160 K200N-EP3 TR20-1E_with_CT1

00N

1.0-1.8 315 S-225S F-225F_or_F-225KB

225 70

150 110 195 K250N-EP3 TR20-1E_with_CT1

00N

1.6-3.2 400 S-400S F-400F 350 95

180 132 230 K300N-EP3 TR20-1E_with_CT1

00N

1.6-3.2 500 S-600S F-600F 500 120

220 160 275 K400N-EP3 TR20-1E_with_CT1

00N

2.5-5 800 S-600S F-600F 500 150

270 200 345 K400N-EP3 TR20-1E_with_CT100N

2.5-5 800 S-800S F-800K 700 185

340 250 428 K600N-EP3 TR20-1E_with_CT100N

2.5-5 800 S-800S F-800K 800 240

STAR-DELTA STARTER1. The Star-Delta starter employ 3-contactor system.2. The motor is a Hitachi standard type squirrel cage 4-pole induction motor.3. The heater range for thermal overload relay are selected from 1/3 = 0.58 of the motor full load current.4. The said wire size indicates IV wire which is able to be connected to the MS & MCd terminals. As for source lone, refer to direct on line stating.

Star Delta Starter in rated 220V 3 Phase 50HzRating

HPRating

KWFull

LoadType Magnet

StarterThermal

OLHeater Range

(A)

Type of Star MCs

Type of Delta MCs

NH Fuse

(A)

S-Series F-Series Rated Curren

t (A)

Wire Size

(sqmm)

5 3.7 13 K10N-EP2_or_ K11N-EP2

TR11-1E 6-12 K11N-EP K11N-EP 35 S-30S F-50F_or_F-50K

30 2

5.5 4 14 K10N-EP2_or_ K11N-EP2

TR11-1E 6-12 K11N-EP K11N-EP 35 S-30S F-50F_or_F-50K

30 2

7.7 5.5 20 K15B-N-EP3 TR20-1E 9-13 K15-BN-EP K15-BN-EP 35 S-50 S-50 50 210 7.5 25 K20B-N-EP3 TR20-1E 12-18 K15-BN-EP K20-BN-EP 50 S-50 S-50 50 415 11 36 K25BN-EP3 TR40-1E 16-24 K15BN-EP K20BN-EP 63 S-100S F-100G 75 620 15 50 K30BN-EP3 TR40-1E 22-34 K20BN-EP K30BN-EP 80 S-100S F-100G 100 1025 18.5 62 K30BN-EP3 TR40-1E 32-48 K25BN-EP K30BN-EP 100 S-225S F-225F 125 1030 22 72 K50N-EP3 TR-100-1E 32-48 K25BN-EP K50BN-EP 100 S-225S F-225F 150 1040 30 100 K60N-EP3 TR-100-1E 45-65 K30BN-EP K60BN-EP 125 S-225S F-225F 200 1650 37 120 K100N-EP3 TR-100-1E 55-80 K50N-EP K100N-EP 160 S-225S F-225F 225 2560 45 145 K120N-EP3 TR-100-1E 65-95 K50N-EP K120N-EP 200 S-400S F-400F 350 3575 55 180 K150N-EP3 TR100-1E 90-120 K60N-EP K150N-EP 200 S-400S F-400F 400 35

100 75 240 K200N-EP3 TR20-1E_with_CT100N

90-120 K120N-EP K200N-EP 0 S-600S F-600F 0 0

125 90 290 K250N-EP3 TR20-1E_with_CT100N

1.0-1.8 K150N-EP K250N-EP 400 S-800S F-800F 700 70

150 110 350 K300N-EP3 TR20-1E_with_CT100N

1.6-3.2 K200N-EP K300N-EP 400 S-800S F-800F 800 120

180 132 410 K400N-EP3 TR20-1E_with_CT100N

1.6-3.2 K250N-EP K400N-EP 500 N/A U-800 800 150

220 160 520 K400N-EP3 TR20-1E_with_CT100N

2.5-5.0 K300N-EP K400N-EP 630 N/A U-1200 1000 185

270 200 710 K600N-EP3 TR20-1E_with_CT100N

2.5-5 K300N-EP K600N-EP 800 N/A U-1200 1200 325

340 250 823 K600N-EP3 TR20-1E_with_C

T100N

2.5-5.0 K400N-EP K600N-EP 800 N/A U-1200 1200 325

Star Delta Starter in rated 380V 3 Phase 50HzRating Rating Full Type Magnet Starter Thermal OL Heater Type of Star Type of NH S-Series F-Series Rated Wire

HP KW Load Range (A)

MCs Delta MCs Fuse (A)

Current (A)

Size (sqmm)

5 3.7 7.5 K10N-EP2_or_ K11N-EP2

TR11-1E 2.5-5.0 K11N-EP K11N-EP 16 S-30S F-50F_or_F-50K

20 1

5.5 4 8.5 K10N-EP2_or_ K11N-EP2


20 1

7.7 5.5 11.5 K15B-N-EP3 TR11-1E 4.5-9.0 K15-BN-EP K11N-EP 20 S-30S F-50F_or_F-50K

30 1

10 7.5 14.5 K15B-N-EP3 TR20-1E 6-12 K15-BN-EP K11N-EP 35 S-30S F-50F_or_F-50K

30 1.5

15 11 21 K15B-N-EP3 TR20-1E 12-18 K15BN-EP K11N-EP 35 S-100S F-50F_or_F-50K

50 1.5

20 15 29 K20BN-EP3 TR20-1E 12-18 K15BN-EP K20BN-EP 50 S-100S F-50F_or_F-50K

50 2.5

25 18.5 36 K25BN-EP3 TR40-1E 16-24 K20BN-EP K25BN-EP 50 S-225S F-100G 75 430 22 42 K30BN-EP3 TR40-1E 22-34 K25BN-EP K30BN-EP 63 S-225S F-100G 100 640 30 55 K30BN-EP3 TR40-1E 22-34 K25BN-EP K30BN-EP 63 S-225S F-100G 100 650 37 68 K50BN-EP3 TR-100-1E 32-48 K30N-EP K50N-EP 100 S-225S F-225F_or_F-

225KB125 10

60 45 85 K50BN-EP3 TR-100-1E 45-65 K50N-EP K50N-EP 100 S-225S F-225F_or_F-225KB

150 10

75 55 105 K60N-EP3 TR-100-1E 55-80 K50N-EP K60N-EP 125 S-225S F-225F_or_F-225KB

175 16


225 25

125 90 165 K120N-EP3 TR-100-1E 90-120 K100N-EP K120N-EP 200 S-400S F-400F 350 35150 110 200 K150N-EP3 TR-100-1E 110-150 K120N-EP K150N-EP 250 S-400S F-400F 400 50180 132 150 K200N-EP3 TR20-

1E_with_CT1000

1.0-1.8 K200N-EP K150N-EP 250 S-600S F-600F 500 50

220 160 300 K250N-EP3 TR20-1E_with_CT1

000

1.6-3.2 K200N-EP K250N-EP 315 S-600S F-600F 600 95

270 200 370 K300N-EP3 TR20-1E_with_CT1

000

1.6-3.2 K200N-EP K300N-EP 400 S-800S F-800K 800 120

340 250 475 K400N-EP3 TR20-1E_with_CT1

000

1.6-3.2 K300N-EP K400N-EP 630 N/A U-800 800 150

Star Delta Starter in rated 415V 3 Phase 50HzRating

HPRating

KWFull Load

Type Magnet Starter Thermal OL Heater Range

(A)

Type of Star MCs

Type of Delta MCs

NH Fuse (A)

S-Series F-Series Rated Current

(A)

Wire Size

(sqmm)5 3.7 7.2 K10N-EP2_or_ K11N-

EP2TR11-1E 2.5-5.0 K11N-EP K11N-EP 16 S-30SZ F-50F_or_F-

50K20 1

5.5 4 8.5 K10N-EP2_or_ K11N-EP2


20 1

7.7 5.5 11.5 K15B-N-EP3 TR20-1E 4.5-9.0 K15-BN-EP K15-BN-EP

20 S-30S F-50F_or_F-50K

30 1

10 7.5 14 K15B-N-EP3 TR20-1E 6-12 K15-BN-EP K15-BN-EP

35 S-30S F-50F_or_F-50K

30 1.5

15 11 21 K15B-N-EP3 TR20-1E 12-18 K15BN-EP K11N-EP 35 S-30SZ F-50F_or_F-50K

50 1.5

20 15 28 K20BN-EP3 TR20-1E 12-18 K15BN-EP K20BN-EP 50 S-30SZ F-50F_or_F-50K

50 2.5

25 18.5 35 K25BN-EP3 TR40-1E 16-24 K20BN-EP K25BN-EP 50 S-100S F-100G 75 440 30 52 K30BN-EP3 TR40-1E 22-34 K25BN-EP K30BN-EP 63 S-100S F-100G 100 650 37 62 K50BN-EP3 TR100-1E 32-48 K30BN-EP K50N-EP 100 S-225S F-225F_or_F-

225KB125 10


150 10


175 16


225 25

125 90 160 K120N-EP3 TR-100-1E 65-95 K100N-EP K120N-EP 200 S-400S F-400F 350 35150 110 195 K150N-EP3 TR-100-1E 90-120 K120N-EP K150N-EP 250 S-400S F-400F 400 50180 132 230 K200N-EP3 TR20_with_

CT100N1.0-1.8 K200N-EP K200N-EP 250 S-600S F-600F 500 50

220 160 275 K250N-EP3 TR20-1E_with_CT1

000

1.0-1.8 K200N-EP K250N-EP 315 S-600S F-600F 600 70

270 200 345 K300N-EP3 TR20-1E_with_CT1

000

1.6-3.2 K200N-EP K300N-EP 400 S-800S F-800K 800 95

340 250 428 K400N-EP3 TR20-1E_with_CT1

000

1.6-3.2 K300N-EP K400N-EP 630 S-800S U-800 800 150

30 22 40 K30BN-EP3 TR40-1E 22-34 K25BN-EP K30BN-EP 63 S-100S F-100G 100 4

Maximum Demand Rule of Thumb Samples Table

Approx. Incoming Amp

Actual % Max.Load Actual % Type Industry type

48.3 5000 48.3 2500 46.73 Submains Gul Technologies ( PCB industry )94.39 3200 94.39 1000 92 Main DB United Cement Silo Erection Project ( Mostly Motors Load Industry )65.87 2500 43.8 1250 28.09 Main DBs Gul Technologies ( PCB industry )

2500 66.22 600 59.84 Gul Technologies ( PCB industry )2500 62.9 600 56.29 Gul Technologies ( PCB industry )2500 90.58 500 88.5 Gul Technologies ( PCB industry )

51.95 1600 51.44 800 34.63 Main MVSB Insulpak Styrotek( Chemical & Easy Burning Industry )

1600 52.46 800 35.5 Insulpak Styrotek( Chemical & Easy Burning Industry )

53.11 1200 63.66 300 56.78 E.S.B (emergency)

Gul Technologies ( PCB industry )

1200 43.07 400 33.53 Gul Technologies ( PCB industry )1200 52.6 MSB Citi Bank ( Bank )

49.68 1000 55.5 MVSB SCS (Software Co.)1000 43.86 Citi Bank ( Bank )

44.57 630 50.41 315 33.69 Silo Feed MCC1

United Cement Silo Erection Project( Mostly Motors Load Industry )

630 38.74 80 33.57 Discharge MCC2

United Cement Silo Erection Project( Mostly Motors Load Industry )

50.36 600 57.43 225 45.45 Gul Technologies ( PCB industry )600 43.29 300 27.62 Submains ST Computer System & Services Ltd.

40.8 400 42 Submains SCS (Software Co.)400 39.6 63 35.9 Power Cee

Form unit DBCiti Bank ( Bank )

45.45 300 45.45 100 35.7 Insulpak Styrotek( Chemical & Easy Burning Industry )

54.075 250 28.28 160 12.43 ST Computer System & Services Ltd.250 79.87 100 70.84 Motor Load Ssangyong Cement

45 225 45 150 21.43 Gul Technologies ( PCB industry )

Approx. Incoming Amp

Actual % Max.Load Actual % Type Industry type

59.53 200 40.65 63 27.84 ST Computer System & Services Ltd.

200 68.96 60 60.87 MVSB Yimeido Cosmetic P.L( Chemical Industry )

200 68.98 60 60.87 Main DB Europe Kitchen ( Restaurant )69.44 125 69.44 60 50 Gul Technologies ( PCB industry )

49.8 100 33.33 60 16.67 Isolator Insulpak Styrotek( Chemical & Easy Burning Industry )

49.8 100 70.42 60 48.78 Insulpak Styrotek( Chemical & Easy Burning Industry )

100 83.33 30 78 Insulpak Styrotek( Chemical & Easy Burning Industry )

100 24 58 11.73 Gul Technologies ( PCB industry )100 25.64 60 12.12 Gul Technologies ( PCB industry )100 66.67 60 44.4 DB-1 United Cement Silo Erection Project ( Mostly Motors Load Industry )100 55.5 60 83.3 Packing DB-2 United Cement Silo Erection Project ( Mostly Motors Load Industry )100 69.93 63 46.25 ST Computer System & Services Ltd.100 54.64 63 30.83 ST Computer System & Services Ltd.100 54.64 63 30.8 ST Computer System & Services Ltd.100 53.47 63 40.21 ST Computer System & Services Ltd.100 47.84 63 25.34 ST Computer System & Services Ltd.100 47.8 63 25.34 ST Computer System & Services Ltd.100 41.67 30 33.3 ST Computer System & Services Ltd.100 40 63 17.87 ST Computer System & Services Ltd.100 25.97 63 12.25 ST Computer System & Services Ltd.100 51.8 63 28.46 Submain Metal Component ( Metal Work )

34 75 34 20 27.5 SSQ Gul Technologies ( PCB industry )50.67 63 67.74 ST Computer System & Services Ltd.

63 62.89 32 53.5 ST Computer System & Services Ltd.63 61.16 ST Computer System & Services Ltd.63 55.7 ST Computer System & Services Ltd.63 50 30 33.33 ST Computer System & Services Ltd.63 47.37 30 32.03 ST Computer System & Services Ltd.63 46.67 32 31.06 ST Computer System & Services Ltd.

63 45.98 32 30.77 ST Computer System & Services Ltd.63 45 ST Computer System & Services Ltd.63 43.15 ST Computer System & Services Ltd.63 43.15 ST Computer System & Services Ltd.63 43.15 ST Computer System & Services Ltd.63 42.85 32 27.82 ST Computer System & Services Ltd.63 38.65 30 26.82 ST Computer System & Services Ltd.

63 35.79 32 22.2 ST Computer System & Services Ltd.63 30.14 ST Computer System & Services Ltd.63 78.78 Lighting DB Yimeido Cosmetic P.L ( Chemical Industry )

50.67 63 78.75 20 66.67 Isolator,A.C,Power

H.S Precision

63 60.57 30 44.59 M.D.F Room Woodland Telecomm63 26.25 SSO,DB SGH ( Hospital )63 25 Light & Power

DBSGH ( Hospital )

63 52.5 Light DB SGH ( Hospital )63 23.3 30 15 Power DB SGH ( Hospital )63 52.5 Light DB SGH ( Hospital )63 81.8 Light/Power/

AC/Iso DBSGH ( Hospital )

63 78.75 Power DB Metal Component ( Metal Work )60 50 32 31.8 Aircon Insulpak Styrotek ( Chemical & Easy Burning Industry )60 66.67 30 50 Aircon Insulpak Styrotek ( Chemical & Easy Burning Industry )

38.9 32 36.78 Insulpak Styrotek ( Chemical & Easy Burning Industry )32 40 ST Computer System & Services Ltd.32 40 ST Computer System & Services Ltd.

44.4 30 35.29 20 15.38 Submains Insulpak Styrotek ( Chemical & Easy Burning Industry )30 46.87 Lighting &

PowerInsulpak Styrotek ( Chemical & Easy Burning Industry )

30 50 30 50 Aircon Insulpak Styrotek ( Chemical & Easy Burning Industry )30 33.33 15 20 Insulpak Styrotek ( Chemical & Easy Burning Industry )30 37.5 20 16.7 ST Computer System & Services Ltd.30 50 15 33.33 Light & Power

DBSGH ( Hospital )

30 66.67 15 33.3 Submains Citi Bank ( Bank )30 42.86 Lighting DB Europe Kitchen ( Restaurant )30 37.5 Lighting DB Metal Component ( Metal Work )

62.5 20 62.5 16 5 Lighting Insulpak Styrotek ( Chemical & Easy Burning Industry )

E-HAND

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