Sri Lanka Institute of Information Technology

ELECTRICAL INSTALLATIONS
(EC 323)
LECTURE 3

CHINTHAKA PATHIRANA B.SC ENG (HONS), MBA (COLOMBO), AMIESL

Connecting power >>> loads
 In general there are several methods of connecting power in to loads such as
machineries, light bulbs, motors, heaters, etc
 Simplest equipment we use on this task is a simple switch which we use
domestically.
Can we use the same principle for all
industrial applications …? No
Why ,,,?
 High starting currents of machines
 High load conditions
 To control with separated control circuits
 To implement automated processes
 To implement remote operation

Therefore we use different types of electrical switches to switch power in to different

types of loads
Relays
A relay is an electromagnetic switch operated by a relatively
small electric current that can turn on or off a much larger electric
current. The heart of a relay is an electromagnet (a coil of wire that
becomes a temporary magnet when electricity flows through it).
In simple terms, a relay is a device that uses an electromagnet to
mechanically pull two connections together to complete a circuit,
in the exact same way your finger mechanically pushes two
contacts together in a toggle switch.
A relay is used wherever a small low power device or power supply
needs to switch on a much larger one, usually completely isolated
from the signals power source, or at a much higher voltage than the
signal could provide.
 When power flows through the first circuit (1), it activates the electromagnet (brown),
generating a magnetic field (blue) that attracts a contact (red) and activates the
second circuit (2). When the power is switched off, a spring pulls the contact back up to
its original position, switching the second circuit off again.
Symbol of a relay
Contactors
When a relay is used to switch a large amount of electrical power through its contacts, it is
designated by a special name: contactor. Contactors typically have multiple contacts,
and those contacts are usually (but not always) normally-open, so that power to the load
is shut off when the coil is de-energized. Perhaps the most common industrial use for
contactors is the control of electric motors.
Contactors are useful in commercial and industrial applications, particularly for controlling
large lighting loads and motors. One of their hallmarks is reliability. However, like any other
device, they are not infallible. In most cases, the contactor does not simply wear out from
normal use. Usually, the reason for contactor failure is misapplication.
Symbols of a contactor
What is the difference between
a contactor and a relay?
 Contactors and Relays perform the same task of switching a circuit. If you see from the
application point of view, you would have seen contactors placed in control panels of
industrial motors or other heavy loads. Whereas, relays are used in low voltage
applications such as switching a LED or tube-light or even actuating a circuit breaker .

 Both are electromagnetic switches and operate under similar principles. The difference
comes if we see from the application perspective. Contactors are used for high voltage
switching purposes whereas relays are used for low voltage switching.
How to select a contactor for your
application
There are 3 key elements to a contactor:

 Main contacts (also referred to as main poles)

 Auxiliary contacts
 Coil (part of the electromagnet used to energize the contactor).
Main pole selection criteria:
 How many required in either normally open (N/O) or normally closed (N/C)
format?
 Current rating in amps.
 Voltage rating
 Duty In the absence of a specific duty, a full description of the nature of the
electrical load (e.g. lighting, resistive heating etc), making current, breaking
current and continuous current through the contacts.

2. Auxiliary contacts selection criteria:

 How many required in either normally open (N/O) or normally closed (N/C)
format? Possibility of time delayed auxiliary contacts with certain product ranges.
 If not used in standard low power signaling application, details as per main poles
required.
3. Coil selection criteria:
 Voltage of coil (Note: The coil is often a different voltage to the main poles).
 AC or DC voltage; Frequency of coil if AC. If DC coil, is low consumption required
 When we design electrical power distribution arrangements we use two types of
diagrams to illustrate the arrangements of the components in a graphical way in
industrial installations.
1. Power flow diagram
In power flow diagrams engineers indicates the flow of electricity to its main
machineries and components starting from the power source and ending at the loads.
2. Control diagrams
In control circuits engineers indicates the logical arrangement of the supporting
devices which are used to control the main power circuit in order to make the desired
functionality.
There are typically two distinct parts of a ladder drawing: the power component and the
control component. The power portion consists of items such as the motor, motor
starter contacts and overloads, disconnect(s), and protective devices (fuses and
circuit breakers). The control part encompasses items that make the power
components do their work. For this discussion, we'll focus on the control portion of the
drawing. Let's take a look at the most common components.
Electrical panel boards
Designing
Electrical
Circuits
 Electrical
ladder drawings are still one of the
common and reliable tools used to troubleshoot
equipment when it fails. As with any good
troubleshooting tool, one must be familiar with
its basic features to make the most of the
diagram in the field. In other words, possessing a
basic understanding of how the drawing is laid
out — as well as the meaning of numbers and
symbols found on the schematic — will make
you that much more seasoned as a
maintenance professional.
Importance of having proper
circuit diagrams
 Easiness of assembling and installing
 For costing and estimating purposes
 For maintenance and trouble shooting
 Easy to communicate
 Easy to upgrade
 For training and education
 The most common logic functions are the AND, OR, and NOT functions. Think of a single-
pole light switch in your home that controls a 100W light bulb. The switch can either be off
or on, thereby representing a zero in the off state and a one in the on state. Now imagine
placing two single-pole switches in series to control the same 100W light bulb. In this
condition, switch No. 1 and switch No. 2 have to both be on to light the 100W bulb. This is
an example of an AND operation.
Thermal Overload Relay
 Thermal motor protection relays contain three bimetal strips together with a
trip mechanism in a housing made of insulating material. The bimetal strips
are heated by the motor current, causing them to bend and activating the
trip mechanism after a certain travel which depends on the current-setting of
the relay.
 This circuit is used to start a motor for some industrial process. The components in a 2-wire
control circuit are a maintained contact switching device (S1), a relay coil (M1), and the
thermal overload relay contact (OL). The sequence of operations is fairly simple. When
S1 is closed, the coil of magnetic motor starter M1 is energized and the motor starts,
provided the running overload current is within the values of the overload relay OL. To
stop the motor, S1 is simply opened.
 In this circuit arrangement, the sequence of events could be described as
such. When the pushbutton (PB) is pressed down, the circuit is completed
and current will flow to energize the coil (CR1).
 This circuit arrangement uses all three types of logic functions: AND, OR, and
AND/OR.
 There are certain applications that requires forward and reverse direction of
motor rotation, such as a conveyor system, or perhaps the opening and
closing of valves. Another example is with overhead cranes which would also
require a hoist up and down function, traverse forward and backward, and a
left and right traveling function. Such application would most certainly make
use of a forward and reverse motor control which is intended to achieve
clockwise and counter clockwise motor rotational direction.

 The electrical schematic diagram on the right which features a CAD drawing
provides an illustration of the power circuit of a forward reverse motor
controller used in every electrical industry involving industrial process
automation control technology. The diagram appears similar to the DOL
motor controller except for an additional reverse contactor connected in
parallel across the forward contactor.
 The main circuit breaker is the main power supply
switch that provides power to the line side terminals
L1, L2, L3 of the two contactors, awaiting for any of
these two contactors to close to deliver the
voltage to the terminal of the motor U1, V1, W1 in
order to run the motor.
 The forward contactor is configured in such a way
as to run the motor to its normal forward rotation
with L1 connected to U1, L2 to V1, and L3 to W1.
Whereas the configuration of the reverse
contactor is wired in contrast to the configuration
of the forward contactor so as to provide a reverse
rotation of the motor, with L1 to W1 instead U1,
then L3 to U1 instead of W1, while maintaining L2
connected to V1.
Designing panel boards
Important facts to be considered

 Environment conditions (outdoor/indoor)

 Required IP ratings for panel cabinets
 Direction of power entry
 Size of the cabinet
 Door opening methods
 Arrangement of the components
 Indications and alarms
 Esthetic appearance
 Cable termination techniques
 Type of material of the body
 Earthling and grounding
Standard panel cabinets
 ??? Row ??? Way

 Single Row 1 way

 Single Row 2 way
 Single Row 4 way
 Single Row 8 ways
 Single Row 12 Way
 Single Row 16 way
 Single Row 24 way