Course contents

1. Electrical basics -1-

2. Concepts of Phase and line quantities -5-

3. Control panel (Switch gear) -7-

4. Electrical Diagram -11-

5. Transformer basics -12-

6. TIC -13-

7. Sequence controller -15-

8. Motors -18-

Appendix I- Table showing SWG, selection of wires

Appendix II- Current rating for A.C. Motors

Appendix III - Selection Table for Starter / Relay / Fuse / Cable

for DOL Motors

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Terms in Electrical-

1. Voltage

Force behind the flow of electrons in conductors

2. Current

Rate of flow of electrons

3. Resistance
It is the property of a substance due to which it opposes the flow of electricity
(i.e. electrons) through it.
Practical unit of Resistance is ohm
A conductor is said to have a resistance of one ohm if it permits one ampere
current to flow through it when one volt is impressed across its terminals.

Resistance offered by a conductor :-

 varies Directly as its length L.

 varies Inversely as the cross section A.
 Depends on nature of material
 Depends on temperature of conductor

OHM’S LAW
Ratio of potential difference (V) between any two points on a conductor to
the current (I) flowing between them is constant, provided the temp. of the
conductor does not change.
Power

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Power in DC circuit,

Power P = Voltage X Current

= V X I Watt
= I2 X R

A. C. CIRCUIT
A.C. CIRCUITS - SINGLE PHASE

Real Power P = Voltage X Current X Power factor

= V X I X Cos φ Watt
Reactive Power Q = Voltage X Current X Sin φ
= V X I X Sin φ Volt amperes reactive
( Wattless Component of Power )
Apparent power ( S ) = Voltage x current
= V X I Volt amperes
Alternating Current or Voltage : Direction reverses at regular intervals.

Sinusoidal wave
form

-3-
Em - Maximum emf.
One cycle gets completed in 2p ( 360O )

PHASE
It is the fraction of time period of that alternating current, which has elapsed since
the current last passed through zero position of reference.

-4-
 Few Important terms associated with single phase or three phase

systems.

Line
 Phase
 Live
 Neutral
 Earth
 Ground
 Balanced circuit
 Un-balanced circuit

Concept of Star and Delta Connection

Star Connection

-5-

Delta connection
 Concept of line voltage and Phase voltage in star
connection

Line Voltage
V
V Neutral
Phase
Voltage

-6-
What is switchgear ?

Switchgear is a general term covering a wide range of equipment concerned

with switching and protection of electrical circuit
Switchgear is an essential part of power system and also that of any
electrical circuit.
The switching devices are used to make or break the circuits in healthy or in
abnormal conditions

Fault
A fault in an electrical equipment is defined as a defect in its electrical circuit
due to which the current is diverted from the intended path.
Generally caused by breaking of conductors or failure of insulation
Other causes
•Mechanical failure
•Accidents
•Excessive stresses

Fault classification

• Single line to ground fault

• Open circuit
• Line to line fault
• Double line to ground fault
• Three phase fault
Faults cannot be eliminated but can be minimized

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-8-
Switchgear components

 Switches
 Fuses
 Circuit breakers
 Relays
 Isolators
 Lightening arresters
 Current transformers
 Potential transformers

What is a circuit Breaker?

A circuit Breaker is a switching and current interrupting device in switchgear.

The circuit breaker serves two basic purposes
A] Switching during normal operating conditions for the purpose of
operations and maintenance
B] Switching during abnormal conditions such as short circuits and
interrupting fault currents

Different types of circuit breakers

1.Miniature circuit breaker MCB
2.Molded case circuit breaker MCCB
3.Minimum oil CB MOCB
4.Bulk oil CB BOCB

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5.Air circuit breaker ACB and ABCB
6.Earth leakage CB ELCB
7.SF6 circuit breaker SF6CB
Other switchgear components
Isolators- Isolators are disconnecting switches that are used for
disconnecting the circuit in no load (no current) condition. They are installed
near circuit breakers
Lightning arrestors- They divert the over voltages to earth and protect the
equipment from over voltages
CT s and PT s- These are used for transforming the voltage and currents
to a lower value for the purpose of measurement , protection and control

Electrical interlocks- They are provided to ensure the following sequencing

of operation
While opening * Circuit breaker
* Isolator
* Earthing switch
While closing * Earthing switch
* Isolator
* Circuit breaker

Indicators- Indications are provides on panels by

means of panel mountable lamps.

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Relays
Definition: - Relay is a device, which detects an abnormal fault condition by constantly
measuring the electrical quantities, which are different under normal and faulty
conditions.

Properties of a RELAY system

1) Speed :-
Relay system should be as fast as possible
1 to 2 cycles for operating system.
2.5 to 3 cycles for interrupting system.
2) Selectivity :-
Only nearest Circuit Breaker should operate such that minimum part of
the system should get disconnected.
3) Sensitivity :-
The relay should operate for a low value of actuating quantity.

4) Reliability :- Reliable.
5) Simplicity :- The system should be simple in construction and design. Easy for
maintenance. Minimum no. of relays and contacts should be used.
6) Economy :- Too much of protection is also bad.

- 11 -
 Typical wiring diagram of relay operation

Trip Coil

Circuit
Breaker Battery

Tripping
circuit

Relay
C.T. Coil

Relay
operating
circuit
Sensing
circuit

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 TRANSFORMER
What is a Transformer ?
It is a device that
 Transfers electric power from one circuit to another
(Electrical isolation).
 It does so without change in frequency.
 It accomplishes this by electromagnetic induction.

The different types of transformers are

1. Power transformers
2. Instrument transformers

o Potential transformers
o Current transformers

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 Temperature indicator and controller (TIC)
Basic block diagram

Temp
indicator

Controller To ignition
Water Temp
for taking transformer
storage sensor
decisions

• For temperature sensing we can use-

Flame
1. RTD Resistance temperature detectors extinguishing
mechanism
2. Thermistors
3. Thermocouples

• Different ways for temp indicating are

1. Thermometers
2. Electronic displays

• The controller-
This is a device that takes action according to the signals sent by the sensors. If the temp
is sufficient, accordingly signals should go to the switching circuitry for taking necessary
actions (Extinguishing the flame)
The controllers can be simple logic controllers using discrete components or using the
advanced microprocessor technologies. They can simultaneously control the sequence
controller.

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RTD- Resistance Temperature Detectors (Thermoresistive transducers)

For measurement of temperature the basis is that when the temperature of a

material changes, its resistance also changes.
Two categories of such materials are
Conductors i.e. metals- In this case the resistance is directly proportional to
temperature. e.g. Nickel, Copper, Platinum, Tungsten, Silver etc. Devices in which
such materials are used are called as RTDs.
1. Semiconductors- In this case the resistance is inversely proportional to temperature.
The devices are called as thermistors.
Specific resistance- ohm-

Thermistor
cm

Platinum (RTD)

Temperature

It is found that compared to other metals, platinum is a standard material used as a

resistance elements as RTD.
Properties of resistance elements: -
High electrical resistivity
♦ High thermal coefficient of resistivity
♦ Linear resistance temperature relationship
♦ Corrosion resistant
♦ No change in state within reasonable temperature range
Electrical Leads Metal sheath Protective cement

Terminals

Platinum Resistance coil Hollow Ceramic Former

Schematic Diagram of Platinum Resistance Thermometer

Range is – 900C to + 6000C
- 15 -
 Sequence Controller
The sequence controller controls the complete operating cycle for the boiler, Sequence
starts at the ignition of the flame, up to extinguishing flame. Sequence controller works on
220 Volts AC, 50 Hz.
The ignition transformer is important device in the sequence. The rating is 230V-12.5 KV.
VA rating is up to 500 VA to 750 VA. The high voltage creates spark at the contacts to
generate a flame.

The sequence of the operation can be explained through the following steps-
1. When the line voltage is available at terminals L! of sequence controller supply goes
through the NC (Normally closed) contactsS2 to terminal T
2. Through external circuit it returns to terminal TH of the sequence controller. Terminal
TH is normally used for connecting blower pump motor and fuel pump motor.
3. From terminal TH supply goes through fixed resistance R1, relay coil L1 and
condenser C1 to neutral terminal LN.
4. Photocell connected to C & C terminals is in dark and hence does not conduct
resulting in voltage across L1. L1 energises and operates contacts K1S1 and K2S2.
5. Supply is now available at terminal A, for ignition transformer.
6. L2 energises and operates contacts K2S1 K2S2 and K2S3. Contact K2S1 is hold on
contact for coil L2.
7. Supply from terminal A goes to the ignition transformer through the external electrical
circuit and comes back to V. Neutral is connected through K2S3, L2 and LN giving
spark.
8. Supply is also now available at terminal U of the sequence controller which is fed to
the burner solenoid valve through the external circuit..
9. When the flame is established, the photocell senses the light and conducts to de-
energise the relay coil L1. Therefore contacts K1S1 and K1S2 open.
10. Supply to terminal is cut off and ignition transformer is cut off.
11. When the supply to the terminal L1 cuts off due to external control devices, the
sequence controller stops and there will not be any alarm under this condition.

- 16 -
12. When the supply to terminal L1 is restored, the sequence controller conducts a fresh
firing cycle.
13. If the flame extinguishes due to taking over by some safety devices or due to some
unhealthy conditions, the photocell goes in dark and relay coil gets energised. In turn,
ignition transformer is energised and the sequence controller tries to restore the
flame.
14. If flame is not restored within 10 seconds the photocell remains in dark for that much
time.
15. Under such condition, current continues to flow from terminal TH, contact K1S1,
bimetallic strip heats up and due to its action contact S2 changes over.
16. Supply from terminal L1 of the sequence controller now goes to terminal S. An audio
visual alarm connected to this terminal gets supply and sounds.
17. The firing cycle can be started only after manually pressing the resetting button
provided on the cover of the sequence controller.

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 1

1H

C
R1 L1 Photocell

K1S1 R2

LN
K2S1

L2
K2S2
13
U
K2S3
L2

V
K2S2 TR

S2 S

L1

Sequence controller
PETERCEM MA 810

- 18 -
 How Motor works?
It converts electrical energy into mechanical energy.Conversion is
based on principle that when
Current carrying conductor is placed in magnetic field experiences
a mechanical force whose direction is given by FLEMING's Left
hand rule whose magnitude is given by

F = BIL Newton.
This force on each conductor collectively produce driving torque
rotate armature.

- 19 -
 Appendix I
Table showing conversion of SWG of wires to its m.m.
equivalent

SWG m.m. SWG m.m. SWG m.m.

1 7.62 18 1.219 35 0.2134
2 7.01 19 1.016 36 0.1930
3 6.40 20 0.914 37 0.1727
4 5.89 21 0.813 38 0.1524
5 5.39 22 0.711 39 0.1312
6 4.88 23 0.610 40 0.1219
7 4.47 24 0.569 41 0.1118
8 4.06 25 0.509 42 0.1016
9 3.66 26 0.457 43 0.0914
10 3.25 27 0.4166 44 0.0813
11 2.96 28 0.3759 45 0.0711
12 2.64 29 0.3454 46 0.0610
13 2.34 30 0.3150 47 0.0506
14 2.03 31 0.2946 48 0.0468
15 1.83 32 0.2743 49 0.0305
16 1.626 33 0.254 50 0.0254
17 1.422 34 0.23

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Current rating in Amperes as per ISS 692-1965 for Aluminium
conductor 1100 V underground cable

Number and size of wires in mm

Current rating for Current rating for Current rating for
cables laid in ground cables laid in ducts cables laid in air
Nominal area in sq.mm.

Single Single Single

Three Three Three
core core core
Twin and Twin and Twin and
un- un- un-
core multi core multi core multi
armou armou armou
core core core
red red red

6 1/2.80 50 57 48 42 44 40 56 48 40
10 1/3.55 70 74 62 56 60 51 72 66 56
16 7/1.70 90 96 81 76 80 68 94 88 72
25 7/2.24 115 122 107 98 108 90 124 117 97
35 7/5.50 138 147 128 116 130 105 151 141 119
50 19/1.80 172 180 158 140 159 128 184 177 150
70 19/2.24 208 219 192 1700 190 156 227 220 182
95 19/2.50 244 262 224 198 224 184 272 258 224
120 37/2.06 278 302 257 222 254 211 312 298 258
150 37/2.24 316 346 296 249 287 243 358 339 300
185 37/2.50 359 398 336 279 323 278 412 387 348
240 37/3.00 430 485 413 335 397 340 520 492 437
300 61/2.50 466 536 438 358 422 364 570 524 475
400 61/3.00 553 618 513 412 515 425 680 635 545
500 81/2.80 595 - - 445 - - 760 - -
625 91/3.00 670 - - 490 - - 895 - -

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 Appendix II
Current rating for A.C. Motors

Current rating per phase of Induction

B.H.P. of motor
motor Single phase Three phase Three phase
230 V 400 V 440 V
0.125 1.00 0.30 0.30
0.25 1.80 0.70 0.60
0.50 3.50 1.20 1.00
0.75 4.80 1.70 1.40
1.00 6.20 2.00 1.70
1.25 7.40 2.50 2.20
1.50 8.70 2.80 2.50
1.75 10.00 3.20 2.80
2.00 11.80 3.50 3.20
2.50 14.00 4.30 4.00
3.00 17.50 5.00 4.50
4.00 20.00 6.50 6.00
5.00 24.00 8.00 7.50
7.50 36.00 12.00 11.00
10.00 47.00 15.00 14.00
12.50 59.00 19.00 18.00
15.00 70.00 22.00 21.00
20.00 91.00 29.00 28.00
30.00 135.00 42.00 39.00
40.00 183.00 56.00 56.00
50.00 227.00 71.00 66.00

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 Appendix III
Selection Table for Starter / Relay / Fuse / Cable for DOL
Motors

H.P. with Back Typical

Full load
3 phase DOL starter Relay up HRC cable
current
415 V, 50 LT/LK make scale fuse in size in
appro.
Hz Amps. sq.mm.
0.5 1.0 MK1 / ML0 1 – 1.6 6 1.5 / 2.5
0.75 1.5 MK1 / ML0 1.5 – 2.5 6 1.5 / 2.5
1.0 2.0 MK1 / ML0 1.5 – 2.5 10 1.5 / 2.5
1.5 2.6 MK1 / ML0 2.5 – 4.0 10 1.5 / 2.5
2.0 3.5 MK1 / ML0 2.5 – 4.0 15 1.5 / 2.5
3.0 5.0 MK1 / ML0 4.0 – 6.5 20 1.5 / 2.5
4.0 6.2 MK1 / ML0 4.0 – 6.5 20 1.5 / 2.5
5.0 7.5 MK1 / ML0 6.0 – 10 25 2.5
6.0 9 MK1 / ML0 6.0 – 10 25 2.5
7.5 11 MK1 / ML1 9 – 14 25 4.0
10.0 14 ML1 10 – 16 35 4.0
12.5 18 ML2 13 – 21 50 6.0
15 21 ML2 20 - 32 50 6.0
17.5 24 ML2 20 – 32 63 10.0
20 28 ML2 20 – 32 63 10.0
25 35 ML3 28 - 42 80 16
30 40 ML3 28 – 42 100 25
35 47 ML3 / ML4 45 – 70 125 25
40 55 ML3 / ML4 45 – 70 125 25
45 60 ML3 / ML4 45 – 70 160 35
50 66 ML8 60 - 100 160 35
60 80 ML8 60 – 100 160 50
75 100 ML8 60 – 100 200 70
90 120 ML8 90 – 100 250 95
100 135 ML 12 120 – 200 250 95
150 200 ML 12 180 - 300 350 185
200 275 ML 12 180 - 300 500 300/400
225 300 ML 12 180 - 300 600 300/400

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 Tinned Copper Fuse wire Table

S.W.G. Current rating of Fusing Current

Fuse in Amps. Approx.
40 1.5 3
39 2.5 4
38 3.0 5
37 3.5 6
36 4.5 7
35 5.0 8
34 5.5 9
33 6.0 10
32 7.0 11
31 8.0 13
30 8.5 13
29 10 16
28 12 18
27 13 23
26 14 28
25 15 30
24 17 33
23 20 38
22 24 48
21 29 58
20 34 70
19 38 81
18 45 106
17 65 135
16 73 166
15 78 197
14 102 230
13 130 295

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