1.1 Components in Control Circuit 1.1.

1 Biased Switch / Push Button Push button is used as a control element in Control Circuit, to manually cut the power supply. Symbol
Stop Start

Two distinct colors for identification. Red indicates Push Button Stop whereas Green indicates Push Button Start.

To operate the switch, an external force must be exerted to the button. It returns to normal position when there is no more force exerted.

1.1.2 Latching Switch Latching Switch is used as a control element in Control Circuit, to manually cut the power supply. The contact is mechanically latched closed. Symbol
Latching Switch

Two distinct colors for identification. When the red colored switch is pressed, it will cut the power supply. When the green colored switch is pressed, it will close its contact and allowing current through it.

1.1.3 Relay A relay is used to isolate one electrical circuit from another. It allows a low current control circuit to make or break an electrically isolated high current circuit path. The basic relay consists of a coil and a set of contacts. The most common relay coil is a length of magnet wire wrapped around a metal core. When voltage is applied to the coil, current passes through the wire and creates a magnetic field. This magnetic field pulls the contacts together and holds them there until the current flow in the coil has stopped. The diagram below shows the parts of a simple relay.

R Relay Coil

3/4

5/7

Normally Closed contact or Normally Opened contact

3/4

6/8

1.1.4 Contactor Behaves as a magnetic switch. It will either allow or cut the power supply to electrical instruments. The operation is not much different from relay but bigger in size. It has higher current ratings which allow various power rating applications and control. Symbol:
C Contactor Coil

Contactor Contact (Normally Opened / N.O)

Contactor Contact (Normally Closed / N.C)

Contains a Coil and Contacts. There are two types of contact: Main Contacts Normally opened contact type with high current rating (30A ~ 40A). Behave as an electrically latched switch in a main circuit. Auxiliary Contacts Have a lower current rating (5A). Behave as an electrically latched switch in a control circuit. Divided into two types; Normally Opened and Normally Closed contacts and could be added according to the application needs.

1.1.5 Timer Relay Timer relay consists of a coil, contacts and time adjustable knob. When current flows through the coil, it becomes electromagnet. When it reaches a preset time interval, the induced magnetic field will attract the contacts. It has two types of contacts; normally opened and normally closed contacts. Symbol:

Timer Coil Timer Contact (Normally Opened / N.O) Timer Contact (Normally Closed / N.C)

1.1.6 Thermal Over load Relay To protect electrical motor and main circuit from over load current / over current. An over current imposed high current through overload relay. This current exceed rating limit and hence, operate contacts. The tripping mechanism is made of a bi-metal. The bi-metal consists of two metal strips of different temperature coefficients of expansion which are rolled one on the other. It deflects when heated by the current flowing through it which depends on the current magnitude and duration. Symbol:

Normally Open Contact (N.O)

Normally Close Contact (N.C)

1.1.7 Circuit Breaker Miniature Circuit breaker (MCB) will cut off the circuit whenever the current exceeds its rated value. Normally, it will take one to two hours to trip if the current passing through it is 130% to 145% of the rated current (BS EN 60898:1991). Tripping mechanism is similar as Thermal Over load Relay but with an additional mechanism called electromagnetic trip for handling tremendous inrush current. Both 3-phase MCB and 1-phase MCB will be used for a control circuit and a main circuit respectively Abbreviation: MCB SP for single phase MCB MCB TP for three phase MCB Symbol:
Circuit Breaker

1.1.8 Indicator Lamp As an indicator to indicate the state of operation of the circuit. Green or yellow indicates that the circuit is running in a normal mode. Red indicates that there is an overload or tripping in the circuit. In this situation, the main circuit has been cut off from the main power supply. Symbol: Indicator Lamp

1.2 Electrical instruments for trouble shooting 1.2.1 Digital or analog Multimeter. The functions of Multimeter are as follows: i. ii. iii. iv. v. vi. vii. To measure DC Volts, AC Volts To measure DC Current, AC Current To measure Resistance To measure Continuity To test Diode To measure Capacitance and Inductance To measure Frequency

Below is a specification of a Multimeter Sanwa CD800a

DC VOLTS AC VOLTS DC CURRENT AC CURRENT RESISTANCE CONTINUITY CAPACITANCE INDUCTANCE FREQUENCY TRANSISTOR

400mV- 600V 4V-600V Max 400mA Max 400mA 400, 4k, 40k, 400k, 40M Audible indication: 10-120 normal 50nF, 500nF, 5F, 50F,100F

5Hz, 50Hz, 500Hz, 5kHz, 50kHz,100kHz

Start-up/Inspection procedure

Voltage measurement i. ii. iii. Set the function/range switch to desired voltage range Select AC/DC for type of voltage range Connect the red and black test probes to the measured circuit

iv.

If unknown voltage, set switch to the highest range until the satisfactory reading is obtained

v. vi.

For DC, ensure the correct polarity After measurement, release the probes.

Frequency and duty cycle measurement i. ii. Set the function switch at Hz/% function Apply the probes to the measured circuit and read the display

Resistance and continuity measurement i. Set the function/range to the desired resistance or continuity position

ii. iii. iv. v.

Remove power supply from the circuit under test Connect probes to the test point Resistance: Value will be displayed Continuity: Beeper sounds continuously

Capacitance measurement i. ii. iii. iv. Set the function/range to the desired capacitance position Remove power supply from the circuit under test Connect probes to the test point Capacitance value will be displayed

Current measurement i. ii. iii. iv. v. NEVER apply voltage to the input terminals Be sure to make SERIES connection to load Set the function at mA and select either AC or DC Apply the probes to the measured circuit in series with load If unknown current, set switch to the highest range until the satisfactory reading is obtained vi. vii. For DC, ensure the correct polarity After measurement, release the probes.

Safety precautions i. Turn off power supply for certain measurements

ii. iii. iv. v. -

Use caution when working above 60vdc or 30vacrms Dont measure voltage exceeding the limits Keep your finger behind the finger guard on the probe Do not use the meter if the meter or test probes is damaged

Diode measurement

Clamp Tester The functions of clamp tester are as follows: i. ii. iii. To measure AC Volts To measure AC Current To measure Resistance

Below is a specification of a clamp tester model Kyuritsu Test Current AC 200A AC 600A 40-1kHz 2.0% + 5dgt 40-1kHz 50-60Hz 2.0% + 5dgt 1.5% + 3dgt Frequency 50-60Hz Accuracy 1.5% + 4dgt

Current measurement i. ii. Set the range switch to desired position Press trigger to open transformer jaws

iii. iv. v. -

Clamp onto a conductor Keep the transformer jaws fully closed Read and record reading

Safety precaution i. ii. Never use on a circuit above 600VAC Do not apply at a current above 600A. It will damage the instrument due to overheat iii. iv. Do not open battery compartment cover when make measurement Remove test leads when make current measurement

1.2.2 Insulation tester The function of this tester is to measure insulation resistance level between: i. ii. iii. iv. Test Voltage Measuring Range Terminal Voltage Output Current Short Circuit 500VDC 0-200M 500V +20%, -0% from 0.5M to 1000VDC 0-200M 1000V +20%, -0% from 1M to 1.6mA Live conductor to other live conductor Live conductor to earth Live conductor to neutral Equipment insulation

Below is a specification of an insulation tester model Kyuritsu model 3165

1.4mA General purpose

Usage

Natural installation Electronics components

High voltage installation

Acceptable Resistance

Insulation

>1M

>1M

Insulation measurement i. ii. iii. iv. v. vi. vii. Always off the circuit under test Connect the crocodile clip: Black Earth Red Phase, Neutral Press test button Power On lamp will light Read and record the reading