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EDUCATION
Training Unit
Electrical Control 2
Theory
No: EE 015
Training Unit
Electrical Control 2
Theoretical Part
No.: EE 015
Edition:
2008
All Rights Reserved
Editor:
ELECTRICAL CONTROL 2
CONTENTS
Page
Wiring diagram.....................................................................................................4
1.1.1
1.2
1.3
1.4
1.5
1.6
4.1.
4.2.
4.3.
9.1.1.
9.1.2.
9.1.3.
9.1.4.
ELECTRICAL CONTROL 2
LEARNING OBJECTIVES
name and describe schematic diagrams.
draw wiring diagrams complying with standards.
recognize switching symbols and design simple contactor circuits.
state the difference between wiring diagram and complete circuit diagram.
produce a terminal table.
list the types of wiring.
recognize and find minor faults.
ELECTRICAL CONTROL 2
SCHEMATIC DIAGRAMS
1.1
Wiring diagram
Each piece of equipment is lettered to indicate its type. 1f here are several items of the
same type of equipment, they are given consecutive numbers. A further letter indicates its
general function, e.g., K 2 A auxiliary contactor and K 4 M main contactor (motor
contactor).
1.1.1
a) The current paths are drawn vertically, in between the horizontally drawn bus bars.
c) The direction of the current flow should always be from top to bottom.
e) Apparatus and equipment must be represented in zero volt condition (switched off).
Exceptions have to be clearly indicated (i.e. arrow).
f)
Control equipment e.g. coils, signal lamps must be connected directly to the neutral
conductor, or in case of an earthed supply system, to the potential earth neutral (PEN)
conductor.
10
g) Current paths must be numbered consecutively, circuit elements must be placed from
left to right, depending on their sequence of operation. Circuit elements must be
provided with code letters and consecutive numbers.
For clean representation of the various circuit elements, a table can be added below
the wiring diagram.
11
12
1.2
F1
motor fuses
F2
overcurrent relay
K1
motor contractor
M1
3-phase AC motor
13
1.3
F1
motor fuses
K1
motor contractor
F2
overcurrent relay
M1
3-phase AC motor
F3
control fuses
S1
ON-OFF-pushbutton
14
1.4
Lay-out diagram
This is a document for wiring up the components. All equipment is shown in the correct
position.
1.5
Equipment diagram
15
1.6
Terminal table
The terminals shown in the wiring diagram and complete circuit diagram are compiled in
the terminal table into terminal strips. The terminal table contains the cable or wire
numbers, the terminal number, the origin and the destination.
16
Small circuits are built up on boards and are installed in the places provided on the
machines, e.g., star-delta starter circuit.
Cubicles are fixed directly to the machine and contain all control and switching devices.
Freestanding cubicles for large machine tool controls contain e.g. measuring equipment,
switching devices and control devices.
Freestanding contactor boards are used for extensive electrical plants, e.g., rolling mills
and cranes etc.
Control desks contain all the Instruments and control devices on one board, in order to be
able to control a plant from a central position.
17
WIRING OF CIRCUITS
Wiring in ducts:
This is affected by laying wired in plastic ducts. Note:
Always make the ducts large enough.
Back-panel wiring:
Wires are connected on the back of panels.
Note:
When wiring is taken through a panel, grommets should be used, otherwise the wiring
insulation will be damaged.
Flat wiring:
Individual wires are laid next to and above one another in layers.
Quick wiring:
The wires are laid from terminal to terminal (by the shortest path).
18
4
4.1.
ENVIRONMENTAL EFFECTS
Protection against climatic influences
The required control devices may be affected by local conditions. This means that the
prevalent climatic conditions have to be taken into consideration in advance.
The control devices have to work satisfactorily in temperate and dry climates, as well as in
hot climates with high air humidity. If water condenses in a control cubicle due to frequent
temperature changes at high air humidity (changing climate), then control devices will not
function properly. Heaters may be employed to ensure that water is not deposited in the
equipment.
4.2.
Control devices may suffer adverse effects from vermin (e.g. termites). Components made
of materials containing cellulose should be avoided in electrical operating areas, and a
high degree of cleanliness and brightness of illumination should be ensured. It is useful to
employ encapsulated equipment in areas likely to be affected by vermin.
4.3.
There is a corrosive atmosphere in many plants due to the manufacturing processes e.g.
in chemical and electroplating works and steelworks etc.
Metal parts used as contacts must be suitable for the constructional and switching load
requirements. They are male of precious metals or appropriate alloys.
The above considerations do not only apply for contactors and switchgear, but for all
electrical machines and electrical installations.
19
FAULT FINDING
For rated voltages above 42 V up to a voltage of 250 V to earth, work on live parts is only
permitted, if, in order to prevent danger or for other important reasons, it is impossible to
make those parts of the plant dead, on which work is to be carried out. Such work may
only be carried out by an "expert". An expert is one who can judge and recognize possible
dangers based on his technical training, knowledge and experience as well as his
knowledge of the appropriate regulations applying to the work entrusted to him.
Electricians with completed electro-technical engineering training fulfil these conditions.
Note:
Under no circumstances may apprentices work on live parts of a plant.
5.1.
This table includes the faults which occur most frequently on contactors.
CAUSE
REMEDY
Coil defective
Replace coil
20
voltage security
contactors.
Circuit errors.
Broken wire.
Thermal overcurrent trip not operating Set trip to motor operating current. Note
correctly
21
Use
thermistor
protection.
Thermal
Bimetal strip has turned blue or burnt out; Change overload trip. Install fuses suitable
overload due to too high current; short for overload trip.
circuit with wrong (too high) fuse ratings.
Loss of one-phase (motor does not start - it Possibly a burnt-out fuse, loose or broken
hums).
The control wires between contactor and Lower the control voltage. Install contactor
operating device is too long (holds itself in with smaller holding capacity.
due to capacitive currents).
22
Contactor flutters.
fault
on
operating
elements.
Contactor hums
Replace coil.
Magnet surfaces dirty or corroded (after Clean magnet surfaces. Do not file, do not
long period of shutdown).
grease them.
Replace contactor.
23
Symbol
Description
24
25
26
Switches
Symbols
Description
27
Switches, which are actuated by pushing or pulling, normally have an inherent reset force.
It is therefore not necessary to draw the symbol for automatic reset.
In exceptional cases, where switches have latching qualities, the symbol for latching is to
be used.
Switchgear
Symbol
Description
28
Symbol
Description
29
30
31
32
Letter
General function
Auxiliary function
Counting
Differentiation
---
Protection
Test
Alarm
Integration
Pushbutton operation
---
Main function
Measurement
Proportional
Condition
Reset, cancel
Storage, indication
---
Addition
Multiplication
Analogue
Digital
(start, stop,
limits)
33
For example:
34
8.1.
Frequency of switching
Frequency of switching is the number of switching operations (number of switching cycles)
per hour.
35
OPERATING EQUIPMENT
9.1.
The complete system of designation contains four blocks. Each block has a prefix for
designation.
Prefix
-
Consecutive number
Plant
Location
Connection
Function
: A 1 = B4 + D1 K 3 A
or
- K 3 A + D1 = B4 : A1
For small units it is sufficient to quote one or two designation blocks. Normally only the
designation block "Type of operating equipment - consecutive number - function" is used,
so that the prefix can be omitted.
i.e.: instead of - K 3 A only K 3 A
For the designation of "type" an identification letter from the table "identification letters for
type of equipment" must be used.
The consecutive number is obligatory, and must always be stated. In some cases the
number alone might be sufficient to designate operating equipment.
The function relative to other operating equipment is indicated by a letter from the table
"identification letters for general functions".
36
The designation of the function may be omitted if is not required. However it is not
permitted to use the designation "function" by itself.
The designation "plant" is written down only once in a suitable place on the switching
document. The designation of the plant may be omitted if not required.
The designation "location" states, where the operating equipment is located. The
designation of location may be omitted if not required.
37
The designation "connection" has a colon as prefix. The designation of connection may be
omitted if not required.
38
Designation
Block combination
Explanation
= Plant
= C 1 -K 5 A
- Type, consecutive
number, function
+L2:3
=B2+2D4
+ Location
Terminal 3 of component L 2
: Connection
= Plant
+ Location
floor D of plant B 2
- Type, consecutive
- K 2 M. : 11
number, function
: Connection
= Plant
=B3B+D=Q
+ Location
- Type, number, function
3B
+ Location
+ A 2 - S 10 : 4
- Type, number,
function
control desk A 2
: Connection
: Connection
: A 1 = B 4+ D 1 - K 3 A
Terminal A 1 of
= Plant
+ Location
- Type, number, function
39
D 1, plant B 4
EE 015
Electrical Control 2
Theoretical Test
40
ELECTRICAL CONTROL 2
TEST 1
3. Draw an equipment diagram for a contactor with three main contacts and four auxiliary
contacts (two normally closed and two normally open contacts).
41
ELECTRICAL CONTROL 2
TEST 2
1. State four points which have to be observed when designing a wiring diagram.
4. Draw an equipment diagram for a contactor with three main contacts and two auxiliary
contacts (one normally closed and one normally open).
7. Trouble shooting in control circuits must be carried out by experts only. Which persons
qualify under the stipulation of operating instructions for the term "expert"?
42
ELECTRICAL CONTROL 2
TEST 1
(Solution)
1. Representation
symbols.
Simple
2. Wiring-, single-line-, complete circuit-, lay out-, equipment diagram and terminal table.
3.
4. Cable or wire number, terminal number, the origin and the destination.
5. Wires are connected on the back of panels. Always use grommets through the panel.
6. All instruments and control equipment assembled on one panel for purpose of
controlling a plant from one central place.
8. Coil on wrong voltage or frequency; dirt on the mating faces of the magnetic core;
short circuiting ring broken; foreign body in the air gap.
43
ELECTRICAL CONTROL 2
TEST 2
(Solution)
1. The current paths are drawn vertically in between the horizontally drawn bus bars.
Circuit elements must be drawn at right angles to the current path.
The direction of current flow should always be from top to bottom. Crossovers of lines
should be avoided.
Circuit elements must be represented in zero volt condition (switched off).
Control equipment such as coils, signal lamps etc. must be connected directly to the
neutral conductor.
Current paths must be numbered consecutively, circuit elements must be provided
with code letters and consecutive numbers.
2. The complete circuit diagram is the representation of a circuit in all its details.
If the main and control circuits appear in one diagram, it can become unwieldy and
makes fault finding more difficult.
3. Individual wires are laid next to end above one another in layers.
4.
5.
44
7. An expert is one who can judge and recognize possible dangers, based on his
technical training, knowledge and experience as well as his knowledge of the
appropriate regulations applying to the work entrusted to him. Electricians with
completed electro-technical engineering training fulfil these conditions.
8. The operating signal is not correct. Fault on the operating elements. Contactor coil
voltage is incorrect.
45
KEY TO EVALUATION
PER CENT
MARK
88 100
75 87
62 74
50 61
0 49
46