2019

Module 3
Electrical Installation
Training of Trainer Contents

INDONESIAN – FRENCH – KEMENTERIAN PENDIDIKAN DAN KEBUDAYAAN

SCHNEIDER ELECTRIC
PUSAT PENGEMBANGAN DAN PEMBERDAYAAN PENDIDIK DAN
CENTER OF EXCELLENCE FOR TENAGA KEPENDIDIKAN
ELECTRICITY, AUTOMATION Eric Dupont
AND RENEWABLE ENERGY BIDANG MESIN DAN TEKNIK IINDUSTRI CoE EARE
09/01/2019
 INONESIAN - FRENCH – SCHNEIDER ELECTRIC
Centre of Excellence for
Electricity, Automation and Renewable Energy

@PPPPTK BMTI, Jalan Pesantren KM.2 Kel. Cibabat, Cimahi Utara, Cimahi 40513, Jawa Barat

Phone : +62 (0)22 665-2326 x142

In Partnership with :
THE MINISTRY OF EDUCATION – FRENCH REPUBLIC
THE MINISTRY OF EDUCATION AND CULTURE – REPUBLIC OF INDONESIA
SCHNEIDER ELECTRIC FOUNDATION
PT SCHNEIDER ELECTRIC INDONESIA
 [MODULE 3] General Contents

I. General Contents

I. GENERAL CONTENTS .............................................................................................................................. I-1

I. LECTURES & EXERCISES ......................................................................................................................... II-1

LECTURE CONTENTS ............................................................................................................................. ................. II-3

A. LECTURES: ELECTRICAL INSTALLATION .............................................................................................................. II -5
B. EXERCISES: ELECTRICAL INSTALLATION............................................................................................................ II-31
C. RESOURCES : ELECTRICAL INSTALLATION ......................................................................................................... II-47
D. LECTURE: INDUSTRIAL INSTALLATION ............................................................................................................. II-69

I. PRACTICAL ......................................................................................................................................... III-91

PRACTICAL CONTENTS ............................................................................................................................. ........... III-93

A. PRACTICAL: ELECTRICAL INSTALLATION .......................................................................................................... III-95
B. PRACTICAL INDUSTRIAL INSTALLATION ......................................................................................................... III-105

IV. ANNEXES .........................................................................................................................................IV-1

ANNEX CONTENTS ............................................................................................................................................... IV-3

ANNEXES AND RESOURCES ........................................................................................................................... .......... IV-5
ANNEXES FOR ELECTRICAL INSTALLATION.................................................................................................................. IV -6
ANNEXES FOR INDUSTRIAL INSTALLATION ................................................................................................................. IV -7

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II. Lectures & Exercises

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 [MODULE 3] | Lecture Contents Lectures & Exercises

Lecture Contents

A. LECTURES: ELECTRICAL INSTALLATION .................................................................................................. II-5

ELECTRICITY STANDARDS AND RULES ......................................................................................................................... II -6

BATHROOM ELECTRICAL INSTALLATION.................................................................................................................... II-16
ENERGY MANAGEMENT - LIGHTING, CABLE CHOICE................................................................................................... II-21

B. EXERCISES: ELECTRICAL INSTALLATION ............................................................................................... II-31

BUILDING INSTALLATION RULES ............................................................................................................................. II-32

C. RESOURCES : ELECTRICAL INSTALLATION ............................................................................................ II-47

CONDUCTORS AND CABLES ............................................................................................................................. ...... II-48

MAINTENANCE .............................................................................................................................................. II-56
COMMISSIONING OF EQUIPMENT................................................................................................................. II-59

D. LECTURE: INDUSTRIAL INSTALLATION ................................................................................................. II-69

DEVICES IN INDUSTRIAL WIRING ............................................................................................................................. II-70

INDUSTRIAL WIRING - WIRING RULES ..................................................................................................................... II -82
INDUSTRIAL ELECTRICAL DIAGRAM.......................................................................................................................... II -87

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A. Lectures: Electrical Installation

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Electricity standards and rules

Code: TOT-M03-LE-003-MT_001_Ver-
TOT - Training of Trainer 00

Title: Electricity standards and rules # 001

Module: M03 - M3-Building Installation Doc: MT - Master Trainer

Topic: 003 - Domestic Electrical wiring Type of Activity: LE - Lecture
Equipment: 00 - None

Main Objective cpt.3-1 - Drawing and electrical circuit according to the standards
cpt.3-2 - Design an electrical installation for a building
cpt.3-4 - Select the equipment in order to design an electrical circuit
Objectives The trainee will be able to :
Draw an electrical domestic diagram
Duration: 1:30

resources: Docs
- ID Illumination.pdf
Standards :
- Drawing IR Standards

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Domestic and small company

installation.
To design and establish a domestic installation, the electrician has to follow several standards such as
Diagrams, Protection Standards, Cable/Canalisation size…

1. Diagrams in Building Electricity:

There are 4 different diagrams:

- Architectural plan: This diagram represent on the building plan, the position of the electric
equipment and the link between them.
- Single-line diagram: This diagram represents on the building plan the situation of the
conduits and where they are running.
- Multiline diagram: This diagram represents on the building plan, the effective wiring of the
equipment.
- Developed diagram: this diagram represents the different circuits of the installation without
building representation.

1.1.Architectural plan:

The architectural symbols are on annexure pageII-14

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1.2.Single-line diagram

On each conduit are mentioned the number of conductors and theirs name.

1.3.Multiline diagram

Protection shall be represented.

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1.4.Developed diagram

Protection and protecting conductor shall be represented.

2. Wiring rules
In a domestic installation there are:

- A meter
- A main circuit breaker or fuse
- An earth pit
- A consumer unit (main circuit board) with all the protections for the installation
- Sub circuits such as
o Light
o Power circuit (16A sockets)
o Specialised circuit (AC, Heater, …)

The sub circuits can be wiring in:

- Ring circuit
- Radial circuit
- Star circuit

2.1.Light circuit
According to the standards:

- The light circuit has to contain 10 points maximum with a total power of 800 W maximum.
- A minimum of two light circuits shall be provided.
- An protection conductor shall be provide on each light outlet and connected to the ground
- Illumination level shall be in accordance to the standard table in the file “ID Illumination.pdf”
- A switch shall be provided near to the normal entrance at 1.3 m above the floor level.
- On kitchen, the light shall be placed in order to illuminate the working surface
- In bed room, some light shall be controlled from the bed location.

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- For bathroom, use of celling outlet and the switch shall be outside.
- Switch installed outdoor shall be waterproof (IP 55)

2.2.Socket outlet
All plugs and socket outlet shall be 3 pin type

- Adequate number of socket outlet shall be placed suitable in all rooms.

- Only 3 pin 16 A socket outlets shall be used in all sub power circuits.
- The power sub circuit will contained at maximum two sockets outlet and a maximum power
of 3000W.
- If the appliance require more than 16 A, the socket shall be controlled by a double-poles
switch
- Socket outlet should be installed either 25 cm or 130 cm above the floor level.
- No socket outlet should be provided at less than 130 cm in a bathroom.

Minimum number of outlet recommended

Location 16 A socket outlet

Bedroom 1
Living room 2
Kitchen 2
Dining room 1
Garage 1
For refrigerator 1
For Air-Conditioner 1 for each
Veranda 1
Bathroom 1

2.3.Celling Fan
- Celling fan shall be wired to celling rose or special connector
- Celling fan shall be suspended from hooks or shackles with insulators between suspension
and rods
- Celling fan shall be hung not less than 2.75 m from floor level.

3. Protection
- The main circuit board shall contain the master circuit breaker rated 40 A associated with an
RCD of 500 mA or 300 mA
- A RCD shall protect sub circuits.
- A light circuit shall be protected with a 10 A circuit breaker type C.
- A power circuit shall be protected with a 16 A circuit breaker type C.
- A doorbell circuit/control circuit shall be protected with a 6 A circuit breaker type C
- Each sub circuit shall be isolated. The use of double pole device is recommended.
- A proper cabinet shall be provided for the consumer unit and it shall have at least an IP 2X

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- The earthing shall be distributed on every point (light or socket outlet) and connected to an
earthing pit. A disconnector system shall be provided in order to isolate the earthing pit to
realise it measurement.
- All metallic part shall be connected to the earthing wire. This includes metallic frame and
metallic pipe (gaz, water…)

4. Cables and wire

The colours of wire shall be:

- Brown – Phase 1
- Black– Phase 2
- Grey– Phase 3
- Blue - Neutral
- Green – Yellow/green – Earthing

For cross section of wire shall be

- 1.5 mm2 for the light circuits

- 2.5 mm2 for the power circuit
- 4 mm2 or 6 mm2 for power circuit exceeded 16 A.

5. Connectors
Making joint conductor such as britania joint or tee joint can be easy to connect wire but this method
is dangerous and forbidden. An electric connection has to be done with connectors and all
connexions should be accessible for maintenance and modification. A good connexion doesn’t show
any metallic part.

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6. Annexures
6.1.Architectural Symbols
IDENTIFICATION OF SPECIFIC CONDUCTORS
Neutral Conductor Protective Conductor
Combined protective and Three phase wiring with
neutral and protective
neutral conductor
conductor
WIRING
Wiring going upward Wiring going downwards

Wiring passing through Box, general symbol

Connection or Junction box Consumer terminal wiring,

service entrance equipment
Distribution centre, shown with
five conduits
SOCKET OUTLETS

Socket outlet, general symbol Multiple socket (Power)

outlet

Socket outlet (power) with Socket outlet (power) with

protective contact shutter
Socket outlet (power) with Socket outlet (power) with
single pole switch interlocked switch
Socket outlet
(telecommunication) general
symbol
Socket outlet (power) with TP: Telephone
M: Microphone
isolating transformer : Loud speaker
FM: Frequency
communication
TV: Television
TX: Telex
SWITCHES
Switch, general symbol Switch with pilot light

Perod limiting switch, single Switch two poles

pole
Multiposition switch, single Two way switch
pole

Intermediate switch Dimer

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Pull cord switch, single pole Push button

Push button with indicator Push button with restricted

lamp access (glass, cover…)
Period limiting equipment Time switch
Key operated switch,
watchman’s system device
LIGHTING OUTLETS AND FITTINGS
Lighting outlet position shown Lighting outlet on the wall
with wiring
Lamp general symbol, Signal lamp, general symbol
1) If it is desired to indicate the colour, a notation according to the following
code is placed adjacent to the symbol:
 RD =red
 YE = yellow
 GN =green
 BU =blue
 WH = white
2) If it is desired to indicate the type of lamp, a notation according to the
following code is placed adjacent to the symbol:
 Ne = neon ARC = arc
 Xe =xenon Na = sodium vapour FL = fluorescent
 Hg =mercury IR = infra-red
 I = iodine UV = ultra-violet
 IN = incandescent LED = light emitting diode
 EL = electroluminescent
Luminaire, fluorescent lamp, Luminaire with three
general symbol fluorescent tubes
Luminaire with 5 fluorescent Projector, general symbol
tubes
Spot light Flood light
Auxiliary apparatus for Emergency lighting luminaire
discharge lamp on special circuit.
Self-contained emergency
lighting luminaire
MISCELLANEOUS
Water heater, shown with Fan shown with wiring
wiring
Time clock Electric lock
Intercommunication
instrument

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 Lectures & Exercises Bathroom electrical installation | [MODULE 3]

Bathroom electrical installation

Code: TOT-M03-LE-003-MT_003_Ver-
TOT - Training of Trainer 00

Title: Bathroom electrical installation # 003

Module: M03 - M3-Building Installation Doc: MT - Master Trainer

Topic: 003 - Domestic Electrical wiring Type of Activity: LE - Lecture
Equipment: 00 - None

Main Objective cpt.3-1 - Drawing and electrical circuit according to the standards
cpt.3-2 - Design an electrical installation for a building
cpt.3-4 - Select the equipment in order to design an electrical circuit
Objectives The trainee will be able to :
- Identify the risk of electric hazard in a bathroom.
- Implement electric circuit in the bathroom.
Duration: 1:0

resources: Docs:
- http://www.electrical-installation.org
Standards :
- IEC 60364-7-701: Low-voltage electrical installations - Part 7-701: Requirements for
special installations or locations - Locations containing a bath or shower

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1. Preamble:
Bathrooms and showers rooms are areas of high risk, because of the very low resistance of the
human body when wet or immersed in water.

Because of the risk of electric hazard, rigorous and severe regulation and standards have been
edited.

The relevant standard is IEC 60364-7-701.

Three aspects have to be taken in account when designing an electrical installation in the bathroom:

 The definition of zones, numbered 0,1, 2, 3 in which the placement (or exclusion) of any
electrical device is strictly limited or forbidden and, where permitted, the electrical and
mechanical protection is prescribed
 The establishment of an equipotential bond between all exposed and extraneous metal parts
in the zones concerned
 The strict adherence to the requirements prescribed for each particular zones.

2. Classification of zones
Sub-clause 701.32 of IEC 60364-7-701 defines the zones 0, 1, 2, 3 as shown in the following diagrams

fig: 1 Zones 0, 1, 2 and 3 in proximity to a bath-tub

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fig: 2 Zones 0, 1, 2 and 3 in proximity of a shower with basin

fig: 3 Zones 0, 1, 2 and 3 in proximity of a shower without basin

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fig: 4 No switch or socket-outlet is permitted within 60 cm of the door opening of a shower cabinet

fig: 5 Individual showers with dressing cubicles

3. Equipment in zones
 Zone 0: Electrical device or apparatus forbidden.
 Zone1: ultra-low voltage equipment (12V) certified and only light is allowed. The IP shall be
at least IPX4.
 Zone 2: Class II Equipment, devices, apparatus. IPX3 minimum
 Zone3: All equipment authorised, 3 pin sockets, connexion box. IPX1 minimum.

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4. Equipotential bonding

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Energy Management - Lighting, Cable choice

Code: TOT-M03-LE-003-MT_002_Ver-
TOT - Training of Trainer 00

Energy Management - Lighting, Cable

Title: # 002
choice

Module: M03 - M3-Building Installation Doc: MT - Master Trainer

Topic: 003 - Domestic Electrical wiring Type of Activity: LE - Lecture
Equipment: 00 - None

Main Objective cpt.3-1 - Drawing and electrical circuit according to the standards
cpt.3-2 - Design an electrical installation for a building
cpt.3-4 - Select the equipment in order to design an electrical circuit
Objectives The trainee will be able to :
Select the right section of cable
Select the right equipment to control the light
Duration: 1:0

resources: Docs
- Lightning circuits guide Schneider Electric
Standards :
-

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B. Exercises: Electrical Installation

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Building Installation Rules

Code: TOT-M03-PA-003-
TOT - Training of Trainer RE_001_Ver-00
Title: Building Installation Rules # 001

Module: M03 - M3-Building Installation Doc: RE - Resource

Type of Activity: PA - Practical
Topic: 003 - Domestic Electrical wiring
Activity
Equipment: 00 - None

Main Objective cpt.3-1 - Drawing and electrical circuit according to the standards
cpt.3-2 - Design an electrical installation for a building
cpt.3-4 - Select the equipment in order to design an electrical circuit
Objectives The trainee will be able to :
Cliquez ici pour taper du texte.
Duration: 0:0

resources: Docs
-
Standards :
-

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1. Ex1:
1.1.Objective:
Decode technical information, standards and regulations relating to the structure of electrical
installations. interpret information to structure an electrical installation

1.2.Question:
The diagram hereafter shows the circuits in a 1 BHK apartment.

Bathroom

Bedroom
Lighting

Washroom

Sockets

Living room
Kitchen
Main

1.2.1. Power supply

- How is structured the power supply network?
- Why and how should we structure an electrical installation?
- What are the protections that must provide electrical installation?

Which Installation power to choose and opt for what pricing?

1.2.2. Power supply Network

In India, the electricity is provided to the final customer with the following voltages 230V and 400 V.
Houses are usually supplied with a voltage of 230 volts But, in industry, machine can need more
voltage such as: 400 volts

The electrical network is composed of four wires

L1

- 3 conductors named Live or Phase. Their colour are 400V 400V 230V

L2
Brawn, Black, Grey 400V 230V

- The 4th wire is named the Neutral. Its colour is L3

standardized as Black N
230V

We say that there are three phases and one neutral PE

- Between each phases there is 400V

- Between each phases and the neutral there is 230 V

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- In each home, there are 2 wires, they are:

- Between phase and the neutral, the voltage is 230V
- In a workshop, where machines need often 400V, it will be needed to wire 3 phases.
- In fact, as in our hone than in workshop, there is another wire: The protective wire called Earth
wire or protective earth (PE). This wire is very important for the safety of people. It connects the
equipment’s metallic frame to the ground in order to eliminate possible electric shock. Its colour
is Green/Yellow. This connexion to the ground should be associated with an automatic
disconnection device (Residual Current Detector – RCD). The power supply is the alternative
current and the frequency is 50 Hz.

2. Ex2:

2.1.Objective:
- Decode technical information, standards and regulations relating to the structure of
electrical installations.
- interpret information to structure an electrical installation

2.2.Questions:
According to the Standard, the home of Mr Ganesh has a main switch board where all outgoing
circuits are leaving, but :
- What should contain the main switch board?
- How and where it will be put in place?
- How do we have design the electrical installation?

The main switchboard is mandatory in each home (Individual or collective).

The main switchboard include in one place all supply (Power, phone, cable

2.3.The switchboard

2.3.1. Contents :
The main switchboard should contain:

- The control panel with the meter and the main circuit breaker or fuses.
- It should be placed inside the home and accessible
- The main distribution board
- The communication board with power sockets, TV, Phone, internet connections.

2.3.2. Location :
- It shall be fixed at close proximity to the point of entry of supply.
- Open type switch boards shall be placed only in dry situation and in well ventilated rooms.
- Main switch boards shall be installed in rooms or cupboards having provision for locking so as to
safeguard against operation by unauthorized persons.

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- Switch boards shall not be erected above gas stoves or sinks or within 2.5 m of any washing unit
in the washing room.
- Switch board shall not be installed so that its bottom is within 1.25 m above the floor,
- Where so required, the switch boards shall be recessed in the wall.

Equipment’s which are on the front of a switchboard shall be so arranged

that inadvertent personal contact with live parts is unlikely during the
manipulation of switchgears, changing of fuses or similar operations.

Prefabricated

Meter + Main
Cricuit breaker
or Fuses

Main
distribution
board

Sockets

Communication
board

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2.3.3. Distribution board

Q2

AC

Why? : Subdivide an electrical

installation in several circuits limits
the consequences of a failure by cutting
Q21 Q22 Q23 Q24 Q25 Q26 Q27
only the defective circuit (continuity of
service circuits)
Fault

N°1 N°2 N°3 N°4 N°5 N°6 N°7

How ? :

Rules

- Distribution boards shall preferably be of metal clad type.

- Main distribution boards shall be controlled by a linked switch fuse or circuit-breaker. Each
outgoing circuit shall be provided with a fuse on the phase or live conductor.
- Branch distribution boards shall be controlled by a switch fuse or circuit-breaker. Each outgoing
circuit shall be provided with a fuse MCB on the phase or live conductor. The earthed neutral
conductor shall be connected to a common link and be capable of being disconnected
individually for testing purposes. At least one spare circuit of the same capacity shall be provided
on each branch distribution board.
- Triple pole distribution boards shall not generally be used for final circuit distribution. Where use
of triple pole distribution boards is inevitable, individual single phase circuit shall be controlled by
double pole isolator.
- All distribution boards shall be marked ‘Lighting’ or ‘Power’ as the case may be and also with the
voltage and number of phases of the supply.
- The distribution boards for light and power circuits shall be different.

2.3.4. Exercise :
Determine for the Ganesh’s apartment the 7 circuits from the above diagram:

- Circuit N°1 :
- Circuit N°2 :
- Circuit N°3 :
- Circuit N°4 :
- Circuit N°5 :
- Circuit N°6 :
- Circuit N°7

2.3.5. Rule:
- All circuits shall be protected by a 30mA RCD. If there are electronics devices, they will be two
RCD, one type A and one type AC.
- Type AC : Detects alternating earthing leakage current 50/60 Hz

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- Type A: Detects in addition of the type AC, the alternating current including those with direct
current parts. Suits to electronic devices and appliances.
- To determine the number of RCD we can follow the table hereafter
-
Home Aera No, Type and rating of RCD

Aera 35 m² 1x 25 A (type AC ou A) + 1 x 40 A (type A)

35 m² < Aera 100 m² 2x 40 A (type AC ou A) + 1 x 40 A (type A)
Aera > 100 m² 3x 40 A (type AC ou A) + 1 x 40 A (type A)

2.3.6. Exercise :
Determine the number, type and rating of RCD regarding the Ganesh’s apartment:

Aeras (m²)
Room S.
2
Foyer 4.89 m
2
Living 24.57 m
2
Dining 7.86 m
2
Kitchen 9.67 m
2
Utility 1.67 m
2
Toilet 1.52 m
2
Bedroom 1 14.91 m
2
Toilet 1 4.46 m
2
Master Bedroom 15.62 m
2
Toilet MB 4.46 m
2
Bedroom 3 7m
2
Toilet 3 4.46 m

Total area 101.09 m2. : 3 RCD 40A 30mA Type AC + 1 RCD 40A 30mA Type A

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Estimation of Load Requirements Number of Points in Branch Circuits

Lighting

Number of Socket-Outlets

Air-conditioning The power requirements, layout and design of

The general rules for domestic dwellings, by electrical installation shall take into account
and large, the following types of air-cooling the number and type of such equipment.
equipment are used:
a) Evaporative coolers,
b) Packaged air-conditioners, and
c) Room air-conditioners.

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2.4.Sub circuits

2.4.1. Rule :
Each sub circuit should be protected by Fuses or Circuit Breaker. The maximum value is given by the
table below

Rating of the
Minimal cross protection (A)
Nature du circuit Maximum final point in the circuit
section (mm²)
Fusible MCB

Lighting – Fan – 6A socket 10 1,5 10 10

Electric shutters Depending of the protection rating 1,5 10 10

air extraction fan 1 1,5 - 2

Control circuits 1 circuit per function 1,5 - 2

Power sockets 16 A 2 2,5 16 16

Specialized circuit 20 A (washing machine, clothes

1 par appliance 2,5 20 20
dryer, dish washer, oven, …)

Water heater 1 2,5 20 20

Cooker (single phase) 1 6 32 32

Cooker (three phases) 1 2,5 20 20

2.4.2. Exercise:
With the single line diagram on the Ganesh’s apartment, complete the diagram:

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40A
Give the MCB’s rating

16A 10A 10A 16A 20A 20A 20A

1,5 1,5 1,5 1,5 2, 5 2,5 2,5

2.4.3. Rules
Protective devices and switch disconnector
should be placed inside the distribution board. 20% of space should be provided as provision for
future extensions.

2.4.4. Exercise
Determine the number of modules that have to be provided as provision in the distribution board.
The distribution board of Ganesh’s apartment in composed of 4 rows of 13 modules is equipped
with:

- -23 MCB of 1 module each

- 3 30mA RCD of 2 modules each
- 1 Remote control switch, 1 bell, 1 contactor of 1 module each
- 1 transformer and 1 surge delester of 2 modules each
- 2 sockets of 2.5 module each
- Total amount of modules available: 4 x 13 = 52
- In the board: (23 x 1) + (3 x 2) + 3 + (2 x 2) + (2 x 2,5) = 41 modules so 52 – 41 = 11 free modules
- Provision: 11 / 52 = 0,2115 so 21,15 %

2.5.Overview
Mr Ganesh is buying a 3 BHK apartment at Prestige Shantiniketan in Bangalore.

The Prestige group is building the apartment and the architect give to the electrician the
electrical requirement needed in the apartment.

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2.5.1. 3BHK :

Rooms Dimensions Areas

2
Foyer 6’5” * 8’3” – 1.95m * 2.51m 4.89 m
2
Living 12’6’’ * 21’2’’ – 3.81m * 6.45m 24.57 m
2
Dining 7’6’’ * 11’4’’ – 2.28m * 3.45m 7.86 m
2
Kitchen 9’0’’ * 11’2’’ – 2.84m * 3.4m 9.67 m
2
Utility 5’6’’ * 3’3’’ – 1.67m * 1m 1.67 m
2
Toilet 5’0’’ * 3’3’’ –1.52m * 1m 1.52 m
2
Bedroom 1 11’6’’ * 14’0’’ – 3.5m * 4.26m 14.91 m
2
Toilet 1 6’0’’ * 8’0’’ – 1.83m * 2.44m 4.46 m
2
Master Bedroom 12’0’’ * 14’0’’ – 3.66m * 4.27m 15.62 m
2
Toilet MB 6’0’’ * 8’0’’ – 1.83m * 2.44m 4.46 m
2
Bedroom 3 12’6’’ * 12’6’’ – 3.81m * 3.81m 7m
2
Toilet 3 6’0’’ * 8’0’’ – 1.83m * 2.44m 4.46 m

2.5.2. Equipment
The electrical installation in the apartment should have

Standards: Installationshould be following the Indonesian standards

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Equipement
Foyer
- Main circuit board
o Meter
o Master circuit breaker 40A typeC
o RCD 500 mA
- Distribution board
o MCBs
o Transformer for bell
o Remote control swich
o Contactor
- 1 * celling light controlled by 1 way switch
- 1 * wall sconce controlled by 2 ways switches
- 2 * 6A sockets
Living room
- 2 * celling fans
- 2 * celling lights each controlled by 1 way switch
- 5 * wall sconces controlled by 3 push buttons (remote control switch)
- 1 * celling light on the balcony
- 5 * 6A sockets
- 1 * 16A socket
- 1 * 16 A socket (AC)
Dining
- 1 * celling fan
- 1 * celling lights controlled by 1 way switch
- 3 * wall sconces controlled by 4 push buttons (remote control switch)
- 3 * 6A sockets
- 1 * 16A socket
Kitchen
- 1 * celling lights controlled by 2 way switch
- 5 * 6A sockets
- 3 * 16A sockets
- 1 * 20 A socket (Oven)
- 1 * 16A socket (Dish washer)
- 1 * 6A socket (exhaust fan)
Utility
- 1 * celling lights controlled by 1 way switch
- 2* 16A sockets
- 1 * 16A socket (Washing machine)
- 1 * 16A socket (Water heater)
Toilet
- 1 * celling lights controlled by 1 way switch
Bedroom 1 and 3
- 1 * celling fan
- 1 * celling lights each controlled by 2 way switches
- 2 * wall sconces each controlled by 1 way switch
- 4 * 6A sockets
- 1 * 16 A socket (AC)

Toilet 1 and 3 and Toilet MB

- 1 * celling Class II lights controlled by 1 way switch

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- 1 * wall Class II sconce controlled by 1 way switch

- 1 * 6A socket
- 1 * 6A socket (Exhaust fan)
- 1 * 16A socket (Geyser)

Master Bedroom
- 1 * celling fan
- 4 * celling lights (spots) controlled by 4 push buttons (Remote control switch)
- 2 * wall sconces each controlled by 1 way switch
- 1 * celling light on the balcony
- 6 * 6A sockets
- 1 * 16 A socket (AC)
Phone / TV / Internet
- Foyer
o Communication board
o Phone, TV, Internet
- Living room
o TV socket
o Phone socket (RJ45)
o Internet socket (RJ45)
- Dining room
o Phone socket (RJ45)
o Internet socket (RJ45)
- Bedroom 1 / 3 Master
o TV socket
o Phone socket (RJ45)
o Internet socket (RJ45)
- Kitchen
o TV socket
o Phone socket (RJ45)
o Internet socket (RJ45)

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2.5.3. Single line diagram

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C. Resources : Electrical Installation

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Conductors and Cables

Code: TOT-M03-PA-003-RE_002_Ver-
TOT - Training of Trainer 01

Title: Conductors and Cables # 002

Module: M03 - M3-Building Installation Doc: RE - Resource

Type of Activity: PA - Practical
Topic: 003 - Domestic Electrical wiring
Activity
Equipment: 00 - None

Main Objective cpt.3-1 - Drawing and electrical circuit according to the standards
cpt.3-2 - Design an electrical installation for a building
cpt.3-4 - Select the equipment in order to design an electrical circuit
Objectives The trainee will be able to :

Duration: 1:0
resources: Docs
-
Standards :
-

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1. Conductors and Cables:

They are the active part of the electrical links. Their duty is to carry the electrical current.
There is a large range of conductor and cable.

- An insulated conductor is an association between a conductor and insulation

Conductor
Insulation

- A single core cable is an Insulated conductor with one or more protective sheath.

Conductor
Insulation
Protective sheath

- A cable is a bundle of conductors electrically insulated sharing the protective sheath.

Conductor
Insulation
Protective sheath

2. General structure.
A conductor or Cable is made with two essentials parts; each has its own function (conductive or
insulating)

2.1.Conductive part.
Copper Aluminium
2.1.1. Electrical features. 1.72 * 10-8 Ω.m 2.78 * 10-8 Ω.m
Resistivity
The conductor's role is to conduct current, it Density 8.9 2.7
must have a resistivity (ρ) very low to limit Price Expensive Good price
(for neglected) losses by Joules effect ULV, LV
Local network HV and UHV
R = ( * l)/S Use
and Aerial network
Underground

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The cross section depends on the current in the conductor. The cross section standards are from 0.6
to 360 mm2 (J is the density of current in A/mm2)

I=J*S

2.1.2. Mechanical feature.

The conductor should be enough flexible to follow the complicated path of the conduits. There are:

Multi strand conductors are made with several twisted strands. The strands are put in several layers.

- 1st layer = 1 + 6 = 7 strands

- 2nd layer = 1 + 6 + 12 = 19 strands
 - 3rd layer = 1 + 6 + 12 + 18 = 37 strands

- The single strand conductor has one strand and the cross section can be up to 35 mm².

The flexibility of a cable depends of the number of strand for the same conductive cross section. The
flexibility is defined in 6 classes. Class 1: less flexible, class 6 more flexible. We usually use classes 1,
2, 5, 6.

Standards

- Cables for fixed installations: Classes 1 and 2

- The flexibles: Classes 5 and 6
- Copper welding cables: Class 6

Class 1 Class 2 Class 3 Class 4 Class 5 Class 6

médiocre Passable Bon Tres bon Excellent Exceptionnel

Poor Passable good Very good Excellent Exceptional

Solid Conductor Extra-flexible

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Cross section Conductors Cross section Conductors

mm² Class 1 Class 2 Class 3 mm² Class 4 Class 5 Class 6
1.5 1 x 1.38 7 x 0.50 0.5 7 x 0.30 16 x 0.20 28 x 0.15
2.5 1 x 1.78 7 x 0.67 0.75 11 x 0.30 24 x 0.20 42 x 0.15
4 1 x 2.25 7 x 0.85 1 14 x 0.30 32 x 0.20 56 x 0.15
6 1 x 2.76 7 x 1.04 12 x 1.04 1.5 12 x 0.40 30 x 0.25 85 x 0.15
10 1 x 3.57 7 x 1.35 2.5 20 x 0.40 50 x 0.25 140 x 0.15
16 1 x 4.50 7 x 1.70 19 x 1.04 4 20 x 0.50 56 x 0.30 228 x 0.15
25 1 x 5.65 7 x 2.14 19 x 1.35 6 30 x 0.50 84 x 0.30 189 x 0.20
35 1 x 6.60 7 x 2.52 16 x 1.53 10 49 x 0.50 80 x 0.40 324 x 0.20
50 7 x 2.93 19 x 1.78 27 x 1.53 16 56 x 0.60 126 x 0.40 513 x 0.20
70 19 x 2.14 37 x 1.57 25 84 x 0.60 196 x 0.40 783 x 0.20
95 19 x 2.52 37 x 1.78 35 98 x 0.67 276 x 0.40 1107 x 0.20
19 x 2.85
120 37 x 2.03 61 x 1.60 50 144 x 0.67 396 x 0.40 702 x 0.30
150 19 x 3.20 37 x 2.25 61 x 1.78 70 192 x 0.67 360 x 0.50 909 x 0.30
185 37 x 2.52 91 x 1.60 95 266 x 0.67 475 x 0.50 1332 x 0.30
240 37 x 2.85 61 x 2.25 120 342 x 0.67 608 x 0.50 1702 x 0.30
300 37 x 3.20 61 x 2.52 150 266 x 0.85 756 x 0.50 2109 x 0.30
400 61 x 2.85 185 330 x 0.85 925 x 0.50 2590 x 0.30
500 61 x 3.20 240 420 x 0.85 1221 x 0.50 3360 x 0.30
630 127 x 2.52 300 518 x 0.85 1525 x 0.50 4270 x 0.30
800 127 x 2.85 400 672 x 0.85 2013 x 0.50
1 000 127 x 3.20 500 854 x 0.85 1769 x 0.60

2.2.Insulation part: (dielectric)

Insulation performs the insulation between conductors with different voltages and the ground or the
earth. The insulation should have a very high resistivity.
Currently, synthetic plastics have replaced insulator like paper, natural rubber. The main insulation is
made with:

- Polyvinyl chloride (PVC) or polyethylene (PE)

- Chemically cross-linked polyethylene (PRC)

Insulations used are characterized for their rated voltage isolation. The nominal voltage of the cable
must be at least equal to the nominal voltage of the installation (different voltages 250V, 300V, 500V,
750V, 1000V).

Group Name Use Example Price

Synthesis Polyvinyl Chloride (PVC) General use Building Cheap
Cross-linked polyethylene General use Electronic Cheap
(XLPE) High Electronic Expensive
Polytetrafluoroethylene Temperatures Electronic Very expensive
(PTFE) High Voltage Vacuum cleaner Cheap
Kapton Flexibility Halogen Expensive
Butyl rubber (PRC) required
Silicon High
Temperatures
Mineral Mica HV Winding HV Transformer Expensive
Vegetal Cotton Taping Lighting Expensive

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Gas Air Bush-Bar or Aerial lines Free

Aerial

2.3.Protective sheath.
The protective sheath must meet conditions related to the cable environment, such as:

- The temperature;
- The presence of water, dust;
- The possibility of mechanical shocks, etc ....

The mechanical properties of the insulation part are not always sufficient to protect the cable from
external influences. To correct this, the insulation is covering with a protective sheath which must
have characteristics like:

- Mechanical (tensile strength, torsional bending, shock);

- Physical (resistance to heat, cold, moisture, fire);
- Chemical (corrosion resistance, aging).

Underground cables: An underground cable essentially consists of one or more conductors covered
with suitable insulation and surrounded by a protecting cover.

Is used as cladding materials or insulating materials such as PVC and CBP, or metallic materials such
as lead, aluminium, steel strip.

Conductor
PE insulation
Polyvinyl chloride Plastic
Steel layer
Lead
Paper

3. Construction of cables:
The various parts of underground cables are as under as shown in the picture.

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3.1.LV Cable

3.2.HV Cable

4. Number of wire in a pipe:

Whatever the conduit is, the cross section of wire should always be less than 1/3 of the cross internal
section of the conduct:

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S
n.s
3

o n : Nb of wire Yes NO
o s : Cross section of wire including insulation
o S : Internal cross section of the conduit

5. Installation Methods.
5.1.Identification of Installation methods.
The Installation method is the how a conduit is put in place (aerial, surface mounting, flush
mounting…). The installation method influences the cooling quality of the wires. It is very important
to identify the installation method before select the cross section of the wires.

6. Colours in single phase.

Red Phase

Black Neutral

Phase
Yellow/Gre Protective Earth
Blue Neutral

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7. Colours in three phases

Brawn Phase

Black Phase
Grey Phase

Brawn Phase
Black Phase
Grey Phase
Blue Neutral

Brawn Phase
Black Phase
Grey Phase
Yellow/Green Protective
Earth
Brawn Phase
Black Phase
Grey Phase
Blue Neutral
Yellow/Green Protective
earth

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MAINTENANCE
Code: TOT-M03-PA-003-TR_001_Ver-
TOT - Training of Trainer 00

Title: Maintenance # 001

Module: M03 - M3-Building Installation Doc: TR - Trainee

Type of Activity: PA - Practical
Topic: 003 - Domestic Electrical wiring
Activity
Equipment: 00 - None

Main Objective cpt.3-7 - Perform the commissioning of electrical circuit

cpt.3-8 - Perform electrical measurement according to the safety and security rules
Objectives The trainee will be able to :

Duration: 1:0
resources: Docs
-
Standards :
-

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1. STATEMENT OF ELECTRIC FAILURES

Examples Types of failures

Fuse melted, conductor cut ……………………………………………………………

Badly tightened connection, dry weld ……………………………………………………………

Deterioration of the isolator ……………………………………………………………

Abnormal heating of a motor ……………………………………………………………

Defect of isolation due to the humidity ……………………………………………………………

APPLICATION: Indicate in front of every example of breakdown, the type le type of corresponding failure

2. STATEMENT OF TROUBLESHOOTING DEVICES

Type of device Measure

Ohmmeter ……………….…………………………………………………………………………

Voltmeter ………………………….………………………………………………………………

Ammeter …………………………….……………………………………………………………

VAT Testers ……………………………..……………………………………………………………

Oscilloscope ………………………………..…………………………………………………………

Clamp-on ammeter ………………………………..…………………………………………………………

Network analyzer ………………………………..…………………………………………………………

3. TROUBLESHOOTING METHODOLOGY
Reminder: To repair an installation, it is to recondition it operating. This imposes a lot of method and
care. The search for one or several faults to eliminate the cause of the disturbances requires a logical
progress in the progress of the work with the exception of any method creature of habit of repair by
"stroke of luck"

Table extracts from the NF standard X 60-010 defining the vocabulary of maintenance and management of durable
goods

Designation Description
Action to detect through increased surveillance, continuous or not, the appearance of a failure or the
Detection
existence of a faulty component
Localization Action leading to seek precisely the element by which he failure occurs
Identification of the probable cause of the failure with logical reasoning base on a set of information
Diagnostic
resulting from an inspection, from a control or from a test
Fixing Action on a good out of order to put back it in working order, at least temporarily
Reparation Definitive intervention of curative maintenance after failure

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Step 1: Search and location of the faults

Start

This stage can require the presence of voltage

and, possibly, that of the other power sources Breakdown observation
if it exists there.

In LV, it understands the diverse operations of Hypothesi

Elimination of the possible
measurement of the electric values not
cause
requiring the opening of circuits.
Check Ok
Step 2: Elimination of one or several faults,
repair or replacement of the defective
element. Not Ok
Repair
This stage does not require the presence of
voltage and must be made according to the
modalities of the works switched off. Not Ok
Test
Step 3: Settings and checks of the functioning
of the equipment after repair. Ok

The intervention is ended, if the equipment End

works normally:

- With control components assigned normally (pushbuttons, switches)

- With the normal settings (limit switch, level, temperature)
- If every devices of mechanical protection and electrical locking are in service.

APPLICATIONS:

- Inform from the working voucher of the problem the top of documents(report and process of
intervention)
- Inform the frame "noticed faults" of the report of intervention
- Inform columns "issued assumptions" and "Tooling / Measuring tools used" of the process of
intervention

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COMMISSIONING OF EQUIPMENT
Code: TOT-M03-PA-006-RE_003_Ver-
TOT - Training of Trainer 00

Title: COMMISSIONING OF EQUIPMENT # 003

Module: M03 - M3-Building Installation Doc: RE - Resource

Type of Activity: PA - Practical
Topic: 006 - Industrial wiring
Activity
Equipment: 00 - None

Main Objective cpt.3-7 - Perform the commissioning of electrical circuit

cpt.3-8 - Perform electrical measurement according to the safety and security rules
Objectives The trainee will be able to :

Duration: 1:0
resources: Docs
-
Standards :
-

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1. MEASUREMENT TO BE CARRIED OFF

1.1. General procedure of the checks to be carried SWITCHED OFF
During a first commissioning and before carrying out the tests, it is necessary to check:

1st step :

We have to compare the type and the number of contacts used with those planned
in the sheet material reference. We check the number of contacts connected in the
cabinet and on the door.

We have to check the good connection of control systems (connecting of terminals)

by proceeding to a test of continuity (ohmmeter).

Note: the units are open and the lamps removed.

2nd step:

We have to check the range of devices, the validity of protective devices and the choice of fuses.

3rd step:

We check the absence of short circuit between the active conductors (phase, neutral),
upstream and downstream to the protections (ohmmeter).

4th step:

The check of the equipotential connection of the Electric Protections (EP) consist in verifying that all
the EP conductors (green/yellow) are properly interconnected, to metal body and to earth.

5th step:

All devices connected to the system must have a good isolation.

It is necessary to check the resistance between each active conductor and the metal
frames and between each active conductor.

For this test, we use a megohmmeter.

6thstep:

With the ohmmeter, we have to check the continuity of the connections from the
switch to the receivers. All connections on the power devices are controlled.

The motor circuit and the phase sequence must be correct to respect the direction
of rotation of the motor.

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1.2.2- Check procedure of absence of short-circuit

1.2.1. Definition of a short-circuit

It is a very strong overcurrent which originates when two wires of phase, or a wire of phase and the
neutral, are in contact (very low impedance between these two elements).

1.2.2. Check of absence of short-circuit

This check consists in making sure that there is no short-circuit between the active conductors of an
installation before any powering-up.

For that purpose, it is enough to verify the impedance between phases and between phase-neutral
upstream to the protections.

TEST ABSENCE SHORT-CIRCUIT

Used device Test condition

used
…………………………………………………………….... …………………………………………………
………………………………………………………………. …………………………………………………

Impedance value Status Test results

………………………………………… ……………………… …………………………………………………

………………………………………… ……………………… …………………………………………………

Connecting Ohmmeter

Disconnector Cut-circuit with fuse

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1.3.Check procedure of equipotential connection

1.3.1. Definition of equipotential connection

An equipotential connection aims at connecting with the earth connector all the metal pipes (water,
heating, etc.) and all the accessible conductive elements. It allows that no difference of potential can
exist between those various equipments.

The metal ducts, flexible or stiff, and the metal sheaths of wire must not be used as protective
conductors (but must be linked with EP).

The continuity of the circuit of equipotential protection must be insured for

the electric equipments mounted on covers, doors, shutting plates, etc.

It will not be conducted by the closure systems, the support rails, etc.

1.3.2. Realize an equipotential connection in an electricity

cabinet
In a cubicle, a metal mass can be accidentally powered up if an active
conductor is in contact with. A person who touches this carcass risks a
charging.

This connecting allows avoiding that the mass reaches a dangerous potential
with regard to the earth. It is compulsory for all the equipments of class 1, it
is what name the equipotential.

It is also necessary to protect the people of possible defects of insulation and to allow the leakage
currents led by electromagnetic disturbances.

The mesh could be done:

Trough a green/yellow wire
Through a plait

1.3.3. Check of the equipotential connection

The check of the equipotential connection of the Electric Protections (EP) consists in verifying that all
the EP conductors (green / yellow) are well interconnected, to the metal frames and to the earth.

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TEST of EQUIPOTENTIAL CONNECTION

Used device Test condition

…………………………………………………………….... …………………………………………………
………………………………………………………………. …………………………………………………

Impedance value Status Test results

………………………………………… ……………………… …………………………………………………

………………………………………… ……………………… …………………………………………………

OHMMETER CONNECTION

Door connected to EP through plait or green/yellow wire

DEVICES CLASS

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1.4.Procedure of check of the electrical isolation

1.4.1. Definition of a fault of isolation

The fault of isolation arises when the impedance between one of the phases and the electrical
protection (EP) (or a phase and the metal frame of the receiver) becomes very low. That is when a
phase contacts a EP wire or a metal mass.

1.4.2. Introduction
To ensure the smooth running and a perfect safety of devices and electrical installations, all the
conductors are isolated: sheath for wires, varnished for the windings.

When the quality of these isolations decreases, leakage currents can circulate from a conductor to
another one and, according to the importance of the faults of isolation (the worst fault being the
short-circuit), causes damages more or less serious.

An equipment presenting a fault of isolation can break down, burn or causes a fault on the
installation itself and consequently, activates protection devices, that is the cut of all the
installation...

To prevent and be able to protect itself against risks linked to an insufficient isolation or to a
deterioration of the level of the isolation, proceedings must be made. It concern as well the electrical
equipments as the installations on which they are connected.

Those proceedings are realized during the commissioning, on new or renovated elements, then
periodically to see their evolution during the time.

1.4.3. Electrical insulation

An electrical installation, an equipment or both have to have a good isolation to ensure the
protection of the people. The insurance of a good level of isolation allows to guarantee a better
continuity of service.

The isolation results in measurements of resistance between every active conductor and the metal
frames, and between active conductors (installation or equipment switched off).

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1.4.1. Principle of the measurement

We apply, thanks to the controller of isolation or megohmmeter, a direct voltage test and we collect
the resistance value of isolation. The test must be realized under a voltage at least equal to the
voltage of the network feeding the part to be checked. Test voltages in LV are generally of 500V.

ISOLATION MEASUREMENT

Used device Test condition

…………………………………………………………….... …………………………………………………
………………………………………………………………. …………………………………………………

Impedance value Status Test results

………………………………………… …………………………………………………
………………………
………………………………………… …………………………………………………

………………………………………… …………………………………………………
………………………
………………………………………… …………………………………………………

MEGOHMMETER CONNECTION

Remark:

./ The ohmmeter does not allow to realize controls of isolation because the voltage of measurement
is too low and does not give a significant value.

./ The megohmmeter delivers a voltage of 500V to 1000V and can destroy a part of the devices, in
particular the electronic systems. In that case, we have to disconnect these devices and test them
separately.

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./ During the measurement of an isolation with regard to the earth, it is recommended to place the
positive pole of the test voltage on the earth, to avoid problems of polarization of the earth when we
proceed to multiple tests.

MINIMAL VALUE OF ISOLATION RESISTANCE

The minimum values of isolation resistances are defined according to the rated voltage of the tested
circuit and correspond to the requirements of the standard.

1.4.2. Measurement of isolation on electrical installations

Before the commissioning, receivers disconnected, between every active conductor (conductors of
phase and the neutral) to verify that none of them underwent mechanical damage during the
installation.

Before the commissioning, interconnected active conductors, connected receivers, to verify the
isolation of all the conductors with regard to the earth.

1.4.3. Measurement of isolation of a rotating machine

We can check the quality of the isolation of the windings with regard to the earth or the windings
between them.

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We can also check the isolation of the motor connected on the installation, with regard to the earth

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2. MEASUREMNTS AT POWERING (COMMISSIONING)

A running authorized electrician B1V is authorized to realize tests in the neighborhood of the voltage.

He is responsible for his own safety and necessarily has to arm himself before any intervention with
personal protective equipments (PPE).

He must respect the SPI (Safety Permanent Instruction) of the machine on which he intervenes.

1st step:

Using a voltmeter, iIt is necessary to check the power sources arriving

upstream to the devices of protection.

These being opened, it is necessary to note the values of voltage between

phases, and between phases and neutral.

To validate a test, the expected result should be known.

For example, upstream to a disconnecting switch, between phases we have to recover 400V. If the
measured voltage is different from the expected result, the test cannot be validated.

2nd step:

The voltage sources of the upstream network are correct; we can close the
disconnecting head switch to check the power supplies VLVS* primary and secondary
of the transformer. If they are in accordance with the expected results, we move to the
next step.

* VLVS: Very Low Voltage Safety

3rd step:

The sources 400V deactivated; we proceed to the settings of the control devices (attention:
presence of the 400V upstream of the disconnecting switch):

· Clock, Timer,
· Time-switch,
· Variable Speed Drive,
· …

4th step:

If the previous step is validated, the cabinet is closed and locked. IPE are no longer
used. The total test of the equipment can be realized.

If the operation does not comply, the modifications will be carried realized switched off without IPE.

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D. Lecture: Industrial Installation

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 Lectures & Exercises Devices in Industrial wiring | [MODULE 3]

Devices in Industrial wiring

Code: TOT-M03-LE-006-MT_001_Ver-
TOT - Training of Trainer 01

Title: Devices in Industrial wiring # 001

Module: M03 - M3-Building Installation Doc: MT - Master Trainer

Topic: 006 - Industrial wiring Type of Activity: LE - Lecture
Equipment: 00 - None

Main Objective cpt.3-1 - Drawing and electrical circuit according to the standards
cpt.3-2 - Design an electrical installation for a building
Objectives The trainee will be able to :

Duration: 1:0
resources: Docs
-
Standards :
-

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1. Introduction
The control of the industrial process is mainly powered by electricity. To carry out this, electrical
equipment has been designed with particular function. Whatever the load, the voltage, the system
AC or DC… an industrial wiring is setting up with basics function such as Protection, switching,
control…

2. Main basic functions of the equipment for a motor starter system

On most industrial equipment, there are 5 main functions: Disconnection, Breaking, Short-circuit
Protection, Overload Protection, and Switching. To ensure the protection of people and equipment,
all the equipment has to be placed in dedicated enclosure with the IP according to the environment.

2.1.Function of the equipment:

 Disconnection : To ensure the safety of people involved the installation maintenance, the
equipment or a part of the equipment must be disconnected from the power supply. A
padlocking mechanism may be added to the disconnection device to procure more
protection.
 Breaking : The breaking function is mandatory to be able to break the power supply (on full
load) in case of emergency.
 Short-circuit Protection : To avoid accidental damages on the equipment, disturbance on the
network (Unbalance), risk for the people security, the short circuit must be detected and the
faulty circuit have to be quickly opened.
 Overload Protection : Mechanical overloads and supply network faults are the most common
causes of the overload withstood by motors. This results in a considerable increase in current
drawn up by the motor, resulting in excessive temperature rise and greatly reducing motor

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lifetime. It could even lead to destruction of the motor. Motor overload must therefore be
detected.
 Switching : Its function is to make and break the motor supply circuit.

2.2.Devices or equipment used for these functions

Sizing and implementation of these equipments must comply with standards rules. A particular
attention is done on the discrimination and cascading of the protection and breaking.

3. Disconnector / Switch Disconnector / Switch Fuse Disconnector

The use of disconnector is mandatory in industrial wiring. It is used to isolate the electrical panel
from the power supply.

 Disconnector : Its function is to disconnect and isolate an

electrical installation (or a part of electrical installation) to
perform maintenance. It can be padlock. It has a small
interrupting capacity1 (IC). It will be open only if the load is
stopped (no current consumed)

 Switch-Disconnector : It has the same function as the disconnector and in

addition the switching function. It has a high IC and can open circuits with
load running.

 Switch-Fuse-Disconnector : It has the same function as the switch-

disconnector and in addition it carries fuses to protect the equipment

1
IC : Interrupting Capacity : Capacity of contact to open a high current value without damages.

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against short circuit. It has a high IC and can open circuits with load running

The open position of a disconnector must be visible or indicated.

3.1.Symbols:
Disconnector Switch Disconnector Switch Fuse Disconnector

Control circuit Power contacts

Operatin
g handle

Power Fuses

3.2.aM or gG fuses:
 gG Fuses protect against short circuit in an electrical installation, mainly for resistive load.
 aM Fuses protect against short circuit in electrical installation with Inductive load such as
Induction engine or transformer.

3.3.Type of Fuse:
Depending on the local standards, fuses can have different design.

NFC/Din Fuses type BS Fuses CC Fuses type J Fuse type

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3.4.Selection criteria
No of · 1P + N: Phase + Neutral
· 2P: Two Phases

Poles · 3P: Triphase

· 3P+N: Triphase + Neutral

Rated · Rated Voltage Ue; Maximum voltage between 2 poles.

Voltage

Rating · Maximun curent that the device can support without any damages

Fuses Type · gG or aM depending of the load

No of control contact · 1 or 2 control contact

· Type of Operatin Handle

Accesories · Clamping system

· Padlocking system

Switch Fuse Disconnector

reference

3.4.1. Example
Find the reference of Switch Fuse
Disconnector and the fuses to supply a
Pa=10 kW induction motor (cos 0.851,)
with a 3* 400V network and

√3 ∗ ∗ ∗ cos

10 000
√3 ∗ ∗ cos √3 ∗ 400 ∗ 0.851
16.98

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4. Magnetic relay: Protection against

Short Circuit
The magnetic relay is used to detect short-circuits. The
current of the load is going through a coil. If there is no SC,
the current is too week to create a magnetic field. If there
is a SC, the current create a high magnetic field with
attract a lever to open control contact. This contact will
open the control circuit and switch of the system.

4.1.Symbol:

4.2.Thermal Relay: Protection against overload.

As the magnetic relay, the thermal relay is used to protect the equipment against damages due to an
overload.

It contains 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.

The release mechanism actuates an auxiliary switch that breaks the coil circuit of the motor
contactor (Figure 1). A switching position indicator signals the condition “tripped”.

 A = Indirectly heated bimetal strips

 B = Trip slide
 C = Trip lever
 D = Contact lever
 E = Compensation bimetal strip

4.3.Symbol:

Power circuit: Control circuit or

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4.4.Class of the thermal relay:

The class of thermal relay define its behaviour in case of overload and the tripping time.

4.5.Choice of thermal relay:

The thermal relay is chosen depending on the class and the rated current of the load to be protected.

The thermal relay doesn’t open the power circuit, it detect the overload and through its control
contact act on the control circuit to switch off the equipment in fault.

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No of · 1P + N: Phase + Neutral
· 2P: Two Phases

Poles · 3P: Triphase

· 3P+N: Triphase + Neutral

· The class is defined depending on the

Class tripping time at 7.2 times the rating
current.

Thermal relay

4.5.1. Example:
A thermal relay protects an Induction motor with the following specifications: Pa=15 kW,cos 0.8
power supply 3*400V, control circuit voltage 24V ac. Chose the thermal relay. It would be Class 10A

15 000
27
√3 ∗ ∗ cos √3 ∗ 400 ∗ 0.8

Thermal relay: LRD 32, setting at 27 A

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5. Circuit breaker
A circuit breaker is an automatically operated electrical switch designed to protect an electrical
circuit from damage caused by Overcurrent/overload or short circuit. Its basic function is to interrupt
current flow after Protective relays detect faults condition. Unlike a fuse, which operates once and
then must be replaced, a circuit breaker can be reset (either manually or automatically) to resume
normal operation. Circuit breakers are made in varying sizes, from small devices that protect an
individual household appliance up to large switchgear designed to protect high voltage circuits
feeding an entire city. (Wikipedia)

As per the nature of the current, especially in case of short circuit, the circuit breaker has the ability
to cut electric arc. For this, different methods are used:

Low-voltage MCB (Miniature Circuit Breaker) uses air alone to extinguish the arc. These circuit
breakers contain so-called arc chutes, a stack of mutually insulated parallel metal plates which divide
and cool the arc. By splitting the arc into smaller arcs the arc is cooled down while the arc voltage is
increased and serves as additional impedance which limits the current through the circuit breaker.
The current-carrying parts near the contacts provide easy deflection of the arc into the arc chutes by
a magnetic force of a current path, although magnetic blowout coils or permanent magnets could
also deflect the arc into the arc chute (used on circuit breakers for higher ratings). The number of
plates in the arc chute is dependent on the short-circuit rating and nominal voltage of the circuit
breaker.

In larger ratings, oil circuit breakers rely upon vaporization of some of the oil to blast a jet of oil
through the arc.

Gas (usually sulphur hexafluoride) circuit breakers sometimes stretch the arc using a
magnetic field, and then rely upon the dielectric strength of the sulphur hexafluoride
(SF6) to quench the stretched arc.

Vacuum circuit breakers have minimal arcing (as there is nothing to ionize other
than the contact material), so the arc quenches when it is stretched a very small
amount (less than 2–3 mm (0.079–0.118 in)). Vacuum circuit breakers are frequently
used in modern medium-voltage switchgear to 38,000 volts.

Air circuit breakers may use compressed air to blow out the arc, or alternatively, the contacts are
rapidly swung into a small sealed chamber, the escaping of the displaced air thus blowing out the arc.

Circuit breakers are usually able to terminate all current very quickly:
typically the arc is extinguished between 30 ms and 150 ms after the
mechanism has been tripped, depending upon age and construction of the
device. The maximum current value and let-through energy determine the
quality of the circuit breakers. (Wikipedia)

5.1.Current Rating:
Circuit breakers are manufactured in standard sizes. Miniature circuit breakers have a fixed trip
setting. Larger circuit breakers can have adjustable trip settings

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International Standard--- IEC 60898-1 and European Standard EN 60898-1 define the rated current
In of a circuit breaker for low voltage distribution applications as the maximum current that the
breaker is designed to carry continuously (at an ambient air temperature of 30 °C). The commonly-
available preferred values for the rated current are 6 A, 10 A, 13 A, 16 A, 20 A, 25 A, 32 A, 40 A, 50 A,
63 A, 80 A, 100 A and 125 A (similar to the R10 Renard series, but using 6, 13, and 32 instead of 6.3,
12.5, and 31.5 – it includes the 13A current limit of British BS 1363 sockets). The circuit breaker is
labelled with the rated current in amperes, but without the unit symbol "A". Instead, the ampere
figure is preceded by a letter "B", "C" or "D", which indicates the instantaneous tripping current —
that is, the minimum value of current that causes the circuit breaker to trip without intentional time
delay (i.e., in less than 100 ms), expressed in terms of In:

6. The Contactor
A contactor is an electrically controlled switch used for switching an electrical power circuit, similar
to a relay except with higher current ratings. A contactor is controlled by a circuit which has a much
lower power level than the switched circuit.

A contactor is composed on two parts: Power and control part.

Control part Power part Auxiliary contacts

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The power part is composed of contacts (3 / 4) with high Interruption capacity. All contact are closing
or Opening at the same time. They are moved by the coil of the control circuit. When this one is
supplied, it attracts the moving part and the power contacts are closing. In contrary, when the coil is
not powered, a spring move back the moving part and the power contacts are opening. A contactor is
a switch controlled by a coil.

The power part can have 1, 2, 3 or 4 contacts. They can be Normally Open or Normally Closed. The
rating depends on the load current.

The control is divided in two parts: The coil, which can be supplied in ac or dc and several voltages
and the auxiliary contact moving at the same time of the power contacts.

If it is require, auxiliary contact can be added on the contactor’s front or side.

6.1.Contactor choice:
· 1P + N: Phase + Neutral
No of · 2P: Two Phases

Poles · 3P: Triphase

· 3P+N: Triphase + Neutral

Categories · Categories of use define the value of the rating current wich the contactor soulld establish
or cut.
of use · it depends on the load caracterisitc and the opening and closing conditions.

· Ie: is defined according to the voltage rating, the frequency, the service, the
Rating category.

Voltage rating · Ue: maximum voltage between poles

Power · Standarzied Power of the load

Control circuit voltage · Uc: Value of the control circuit voltage, voltage of the coil.

Accessories · Additional contacts, delay, locking system.

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6.2.Categories:
The IEC 947-4 Standard characterises the various category of use of the device control. For the motor
feeder in ac, the mains categories are:

6.3.Symbols:

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Industrial Wiring - Wiring Rules

Code: TOT-M03-LE-006-MT_002_Ver-
TOT - Training of Trainer 00

Title: Industrial Wiring - Wiring Rules # 002

Module: M03 - M3-Building Installation Doc: MT - Master Trainer

Topic: 006 - Industrial wiring Type of Activity: LE - Lecture
Equipment: 00 - None

Main Objective cpt.3-1 - Drawing and electrical circuit according to the standards
cpt.3-2 - Design an electrical installation for a building
Objectives The trainee will be able to :

Duration: 1:0
resources: Docs
-
Standards :
-

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1. Hardware location:
To implement the devices on a mesh in cabinet, it is recommended following the rules hereafter:

1.1.Space between devices:

 Wiring by using raceway: leave 4
to 6 cm between the devices and
the raceway.
 Wiring in strand: Leave 4 to 6 cm
between devices

1.2.Common functions:
 it is recommended to place side
to side the equipment with
common function e.g. contactor
forward / reverse, contactor
going up / down…
 The rating plate of the contactor
coil should be accessible for
reading.

2. Wire colour:
For the power circuit the following colour should be used:

 Phase 1: Brawn (red)

 Phase 2: Black (Yellow)
 Phase3: Grey (Black)
 Neutral: Blue
 Earthing: Yellow /green

Note that the phases can be wired with one colour; in this case, the marking is mandatory.
The control circuit will be wired in grey. Other colour can be used but the marking is mandatory.

3. Connection of equipment

3.1.Contact:
 The input must be on the top or left of the devices, the output on the bottom or right.

3.2.Control box:
 Input on the left, output on the right

3.3.Coils:
 Input – A1, output – A2

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4. Connexion:
The size of the wire depends on the current that it will carry. Usually, the cross section of the wire is
0.75 mm2 for the control circuit and 1.5 mm 2 for the Power circuit. The size should be adapted to the
current.

Cross section (mm2) 0.5 0.75 1.0 1.5 2.5 4 6 10 16

Current max( A) 3 6 10 16 25 30 40 60 80

4.1.Preparation of the wires:

 Set up the stripping plier to prevent to cut the wire or strands.
 Remove the right length of insulation.
 Slight twist of the strand wires.
 The wire ends should have lugs to procure a good connection. The ferrule is
clamped with dedicated tools. If the terminal is a spring type, lugs are not
required.
 Prevent to put strand outside the connector.

4.2.Connexion to terminal
The position of the wire is important. The wire must be place according to the tightening direction of
the connector:

Tightening Tightening
direction direction

Tightening
direction
Tightening
direction

 If there is two wire, place them on both sides of the terminal

 Note that two wire maximum must be connected to one terminal.

4.3.Wiring rules:
Regarding the wiring in raceway, the following rules must be followed:

 Wire the power circuit before the control circuit.

 For the control circuit: wire first the coil return (A2 terminals) then the button box, then the
cabinet door and finally the mesh.
 The bridge between two terminals should be run through the raceway.

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 The length of the wire should be enough to shape it.

 Wire must come perpendicularly to the device or
terminal
 Wire terminal block from left to right and from top
to bottom.
 For a comb wiring, wire must be parallel

 The link to the loads, sensors should be made by

cables.
 The identification of the wire is given by the equipotential number on the diagram. This
identification can be letters, numbers or both. The identification is made with ring, clips or
direct printing.

 All devices should be marked with specific tag.

 Check the tightening.

4.4.Wiring procedure
 Check with Multimeter the state of the contact
 Wiring the horizontal connection then each load.
 Mark each wire when it is out in place. Reading from bottom to top or left to right.
 Identification must be at 5 to 10 mm from the terminal.
 Tick on the diagram the wire put in place.

5. Electrical file
At the end of the wiring, an electrical file must be provided. It contents:

 List of the folios (numbered: ( no folio)/(total no of folio);

 Developed diagram

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 List of equipment
(nomenclature)
 Cable list and connexion

The electrical file should be stored inside the cabinet.

6. Example
6.1.Sample diagram:

6.2.Real wiring diagram

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Industrial Electrical diagram

Code: TOT-M03-LE-006-MT_003_Ver-
TOT - Training of Trainer 00

Title: Industrial Electrical diagram # 003

Module: M03 - M3-Building Installation Doc: MT - Master Trainer

Topic: 006 - Industrial wiring Type of Activity: LE - Lecture
Equipment: 00 - None

Main Objective cpt.3-1 - Drawing and electrical circuit according to the standards
cpt.3-2 - Design an electrical installation for a building
Objectives The trainee will be able to :

Duration: 1:0
resources: Docs
-
Standards :
-

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 Lectures & Exercises Industrial Electrical diagram | [MODULE 3]

1. Introduction
Electrical diagram is the part of the industrial system. It is one of the first steps in the design process
of an industrial system or machine. It is not an architectural representation (in industrial), it shows
the devices used in the system and the connections between them. Symbols used have been
designed and standardized to be readable by every technician.

2. Symbols used
There are plenty of symbols representing an electrical device. To be able to
be read by every technician, symbols were standardized and an international
standard created: The IEC IEC60617 – part 7. Local standards have been
designed by following the IEC one. For India, in Electricity, the standards are:
is.12032.1, is.12032.2, is.12032.3, is.12032.4, is.12032.6, is.12032.7,
is.12032.8.

The target of the electrical diagram is the readability of the operation of the
different circuits (Control, Power … circuits)

3. Symbolization of devices
Mechanical link

Control part Power part Auxiliary contacts

 Main contacts: Power circuit

o From 0 (control device) to 4 power contacts.
o Always represented together, they are drawn in solid line
 Auxiliary contacts: Control circuit
o From 0 to 5 contacts, more with the use of add
o Ungrouped, drawn in fine line
o 2 types: Normally Open (NO), Normally Closed (NC)
o Mechanically linked to the control part they indicate the state of the device. By this,
the state of a device can be used in a control circuit.

 Control part (control of the contacts) Operated by Pushing

Manual: drawn on the contact’s left side.
-4o
Electric (coil) load of the control circuit
-4o
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 Mechanical link:
o Partially drawn if it disturbs the reading of the electrical diagram.

4. Identification of the device terminals

 Power contact:
o Single or double poles device: Identification mark => 1 – 2, 3 – 4.
o Three poles or tetrapolar device: Double identification mark => 1/L1 – 2/T1; …

 Control contacts:
o The units digit designate the function of the contact:
 Normal – NC => 1 – 2
 Normal – NO => 3 – 4
 Special (thermal, delayed, etc.) – NC => 5 – 6
 Special (thermal, delayed, etc.) – NO => 7 – 8
o The tens digit designate only for the multi-contacts device by
design the order of the contact. E.g. 13 – 14 => fist contact (NO) of
the device, 21 – 22 => second contact (NC) of the device…
 Control part:
o Coil: A1 – A2
o Pilot Lamp: X1 – X2

 Terminal board: X (Si terminal board) . (Si terminal)

 Terminal board: X (Si terminal board) . (Si terminal)

5. Equipotential identification of wires:

 Rules:
o Unique number for all conductors with the same potential
o Incrementation (+1) on each device on the reading direction (left to right / top to
bottom)
o Power circuit: number preceded by the type of conductor (L, N, PE)

6. Cross Reference unbundled symbols

 The location of the equipment is given by the coordinates on the folio frame.
o E.g. 02 – G5 => Folio 02 – Column G, Row 5

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 Below the master symbol, list of the slave symbols

 On the slave right symbol, the references of the master symbol.

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 [MODULE 3] Practical

III. Practical

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 [MODULE 3] | Practical Contents Practical

Practical Contents

A. PRACTICAL: ELECTRICAL INSTALLATION ............................................................................................. III-95

HOTEL ROOM ...................................................................................................................... ............................. III-96

HOTEL ROOM – PRIVACY-CLEANING-WAIT ............................................................................................................ III-99
HOTEL ROOM - OCCUPANCY SENSOR .................................................................................................................. III-101

B. PRACTICAL INDUSTRIAL INSTALLATION ........................................................................................... III-105

DOL TWO DIRECTION CONTROLLED BY INTEGRATED SYSTEM ..................................................................................... III-106

SOFT STARTER............................................................................................................................. .................... III-110
INDUCTION MOTOR CONTROLLED BY VSD ............................................................................................................ III -114

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A. Practical: Electrical Installation

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 Practical Practical: Electrical Installation | [MODULE 3]

Hotel Room
Code: TOT-M03-PA-003-
TOT - Training of Trainer TR_0001_Ver-00

Title: Hotel Room # 0001

Module: M03 - M3-Building Installation Doc: TR - Trainee

Type of Activity: PA - Practical
Topic: 003 - Domestic Electrical wiring
Activity
Equipment: 00 - None

Main Objective cpt.3-1 - Drawing and electrical circuit according to the standards
cpt.3-2 - Design an electrical installation for a building
cpt.3-3 - Implement electrical wiring according to the standards
cpt.3-4 - Select the equipment in order to design an electrical circuit
cpt.3-5 - Establish the list of required equipment in order to make the electrical wiring of a
building
cpt.3-6 - Establish the quote of a designed wiring
cpt.3-7 - Perform the commissioning of electrical circuit
cpt.3-8 - Perform electrical measurement according to the safety and security rules
Objectives The trainee will be able to :
Design, set up, commission, testing and doing maintenance
Duration: 12:0

resources: Docs
- Pieno_E8231EKT_WE_G1.pdf
- Kontactor_Acti 9 iCT_A9C22715.pdf
- Kontactor_Acti9 Contactor Din Katalog Indonesia.pdf
- Kontactor_Contactor Din Instruction Sheet_ID.pdf
- ABL8REM24030_DATASHEET_ID_en-GB.pdf
- DIA3ED2170401EN.pdf
- Smart Relay - Zelio Logic Catalog 2018.pdf
- Smart Relay - Zelio Logic SR2_SR3_SR3B261BD.pdf
- Smart Relay - Zelio Logic SR2_SR3_SR3B261BD-Instruction sheet.pdf
Standards :
-

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1. Preamble:
This activity will be able to assess skills and knowledge about:

 Designing an electrical diagram

 Select the equipment required for the exercise
 Setting up the electrical installation
 Programing a smart relay
 Perform the commissioning and testing of the installation
 Perform a maintenance and troubleshooting research

2. The hotel room

In a hotel, the management wants to renew the electrical installation of the rooms and corridors.

The electrical equipment is as follow:

 Room
o A card reader is at the entrance of the room. Inserting a card will power all the room.
All lamps are lighting and all sockets are powered. Removing the card will cut the
power after 30s.
o A master switch will switch off or switch on all lights. It is placed on the left of the
bed.
o The central light is controlled by two push buttons (On the left of the bed, one at the
entrance.
o The bed light is controlled by a switch on the left of the bed
o The bathroom light is controlled by a switch outside the bathroom, at its the
entrance.
o A power socket is on the right of the bed with an phone socket
o A Ethernet socket is opposite of the bed
o A power socket for the TV and the TV Socket are on the wall opposite the bed, with
the Ethernet socket.
 Protection
o People protection with RCD 300mA for the room.
o An additional RCD 30mA is dedicated to the bathroom light and Sockets.
o Power sockets are protected by C16 MCB
o Lights are protected by C10 MCB
 The smart Relay
o The control of the room is done with a smart relay “Zelio” ref SR3B261BD (24VDC)
o The Zelio is powered through an AC/DC power supply.
o A 24V DC power supply is used to supply the Zelio and its inputs
o The Zelio is protected by a C4 MCB and the DC power supply by a C2 MCB
o The Zelio’s input/output are defined as follow:
 Input
 I1 – Card information through a contactor

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 I2 – Push Button 1
 I3 – Push Button 2
 I4 – Bathroom Push Button
 I5 – Bed Push Button
 I6 – Master Push Button
 Output
 Q1 – Central Light
 Q2 – Bed Light
 Q3 – Bathroom Light
 Q4 – Socket 1
 Q5 – Socket 2

3. Work to do
 According to the specification on §2, draw the electrical diagram on the installation and the
input/output diagram of the Smart Relay.
 With the software “Zelio Soft2” creates the program to control the room installation
 Establish the list of required equipment
 Collect the equipment and set up the installation according to the architectural layout
 With the presence of the master trainer, perform the commissioning.
 Test your installation, fix the error if needed.
 Perform a troubleshooting research on another installation.

4. Architectural diagram

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Hotel Room – Privacy-Cleaning-Wait

Code: TOT-M03-PA-003-
TOT - Training of Trainer TR_0002_Ver-00

Title: Hotel Room – Privacy-Cleaning-Wait # 0002

Module: M03 - M3-Building Installation Doc: TR - Trainee

Type of Activity: PA - Practical
Topic: 003 - Domestic Electrical wiring
Activity
Equipment: 00 - None

Main Objective cpt.3-1 - Drawing and electrical circuit according to the standards
cpt.3-2 - Design an electrical installation for a building
cpt.3-3 - Implement electrical wiring according to the standards
cpt.3-4 - Select the equipment in order to design an electrical circuit
cpt.3-5 - Establish the list of required equipment in order to make the electrical wiring of a
building
cpt.3-6 - Establish the quote of a designed wiring
cpt.3-7 - Perform the commissioning of electrical circuit
cpt.3-8 - Perform electrical measurement according to the safety and security rules
Objectives The trainee will be able to :
Design, set up, commission, testing and doing maintenance
Duration: 12:0

resources: Docs
- Hotel devices wiring.pdf
- Pieno_E8231BPDMW_WE.pdf
- Pieno_E8233DMWS_WE_G11.pdf
Standards :
-

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1. Preamble:
This activity will be able to assess skills and knowledge about:

 Designing an electrical diagram

 Select the equipment required for the exercise
 Setting up the electrical installation
 Programing a smart relay
 Perform the commissioning and testing of the installation
 Perform a maintenance and troubleshooting research

2. The hotel room

In a hotel, the management wants to renew the electrical installation of the rooms and corridors.

The electrical equipment is as follow:

 Room
o Three buttons near the entrance in the room will control the three indicators in the
corridor (Privacy, Cleaning, and Wait).
 Protection
o People protection with RCD 300mA for the room.
o Switches and indicators are protected with C10 MCB

3. Work to do
 According to the specification on §2, draw the electrical diagram on the installation.
 Establish the list of required equipment
 Collect the equipment and set up the installation according to the architectural layout
 With the presence of the master trainer, perform the commissioning.
 Test your installation, fix the error if needed.
 Perform a troubleshooting research on another installation.

4. Architectural diagram

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Hotel Room - Occupancy Sensor

Code: TOT-M03-PA-003-
TOT - Training of Trainer TR_0003_Ver-00

Title: Hotel Room - Occupancy Sensor # 0003

Module: M03 - M3-Building Installation Doc: TR - Trainee

Type of Activity: PA - Practical
Topic: 003 - Domestic Electrical wiring
Activity
Equipment: 00 - None

Main Objective cpt.3-1 - Drawing and electrical circuit according to the standards
cpt.3-2 - Design an electrical installation for a building
cpt.3-3 - Implement electrical wiring according to the standards
cpt.3-4 - Select the equipment in order to design an electrical circuit
cpt.3-5 - Establish the list of required equipment in order to make the electrical wiring of a
building
cpt.3-6 - Establish the quote of a designed wiring
cpt.3-7 - Perform the commissioning of electrical circuit
cpt.3-8 - Perform electrical measurement according to the safety and security rules
Objectives The trainee will be able to :
Design, set up, commission, testing and doing maintenance
Duration: 12:0

resources: Docs
- CCT551011_CCT551012_HW_2016_38_EN.pdf
Standards :
-

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1. Preamble:
This activity will be able to assess skills and knowledge about:

 Designing an electrical diagram

 Select the equipment required for the exercise
 Setting up the electrical installation
 Programing a smart relay
 Perform the commissioning and testing of the installation
 Perform a maintenance and troubleshooting research

2. The hotel room

In a hotel, the management wants to renew the electrical installation of the rooms and corridors.

The electrical equipment is as follow:

 Corridor
o The corridor’s lights of the hotel are controlled by an occupancy sensor. It is
detecting the presence of people in the corridor and control the 2 light accordingly
o A push button is used as remote control.
 Protection
o People protection with RCD 300mA for the room.
o Lights are protected by C10 MCB

3. Work to do
 Study the document “CCT551011_CCT551012_HW_2016_38_EN_.pdf” and According to the
specification on §2, draw the electrical diagram on the installation.
 Establish the list of required equipment
 Collect the equipment and set up the installation according to the architectural layout
 With the presence of the master trainer, perform the commissioning. The occupancy sensor
must be on Test position.
 Test your installation, fix the error if needed.
 Set up the occupancy sensor to use only the IR sensor. Test it
 Set up the occupancy sensor to use only the US sensor. Test it
 Set up the occupancy sensor to use the IR and the US sensor. Test it
 What is the effect of the setting of “Lux”
 Perform a troubleshooting research on another installation.

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4. Architectural diagram

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B. Practical Industrial Installation

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DOL two direction controlled by integrated system

Code: TOT-M03-PA-006-TR_004_Ver-
TOT - Training of Trainer 00

DOL two direction controlled by integrated

Title: # 004
system

Module: M03 - M3-Building Installation Doc: TR - Trainee

Type of Activity: PA - Practical
Topic: 006 - Industrial wiring
Activity
Equipment: C03 - Industrial devices for wiring.

Main Objective cpt.3-1 - Drawing and electrical circuit according to the standards
cpt.3-3 - Implement electrical wiring according to the standards
cpt.3-4 - Select the equipment in order to design an electrical circuit
cpt.3-5 - Establish the list of required equipment in order to make the electrical wiring of a
building
cpt.3-7 - Perform the commissioning of electrical circuit
Objectives The trainee will be able to :

Duration: 4:0
resources: Docs
- A4 - TeSys U_P_EN.pdf
- A4 - TeSys U_P_EN-Wiring.pdf
- TeSys U_1629984_01A55.pdf
- TeSys U_1639084_01A55.pdf
- TeSys U_163884301A05-10.pdf
Standards :
-

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1. List of Equipment
 Wiring Bench
 Power supply
o Connectors blocs
o 1 MCB C10 4P and 1 RCD 30mA 4 P)
o 1 MCB C4
o 1 MCB C2
o 1 transformer 230-400V:24V
 Tool set
 Tesys U pack
o Power base LUB120
o Auxiliary contacts LUA1C20
o Auxiliary contacts LUFN11
o Control Unit LUCA05B
o Reverse bloc LU2MBOB
o Connector block LU9M1
o Pre-wiring block LU9MR1C
 1 Box 3 Push buttons XAL D311
 1 Box 8 holes for push buttons and pilot lamps XAP A2108
 2 Push Buttons with 1 NO and 1 NC each
 1 Push button with 1 NC
 1 Pilot lamp Red
 1 pilot lamp Yellow
 1 pilot lamp Green
 Set of connectors
 Set of wires
 Set of number
 Computer + QElectrotech Software

Symbols:

Work to be performed Information / Tip

Teacher/Professor required Danger

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2. Preamble
The Direct on line starter is to control an induction motor. The control circuit is usually composes
with Switch Disconnector, Fuses or Magnetic Relay, Contactors and overload relay. All of these
devices have the target to control the power supply of the motor and to protect the equipment
against overload and short circuits. For a 2 direction control, additional equipment is required.

3. Task 1
With the help of the software QElectrotech, design, according to the standard, a DOL 2 direction
circuit to control an Induction Motor.

The devices used must be

 Q1: Switch disconnector with Magnetic relay

 KM1: Contactor (Forward)
 KM2: Contactor (Reverse)
 F1: Overload Relay
 S0: Emergency Stop Button
 S1: Stop Push Button
 S2: Forward Push Button
 S3: Reverse Push Button

Q 1. What is the function of each device?

Q 2. How many wires do you need to do the wiring?

4. Task 2
Manufacturers of industrial devices have created new integrated equipment to control motors.
Schneider Electric created the Tesys U system to do that.

By studying the recourse document “A4 - TeSys U_P_EN.pdf” pages A4/2 to A4/9, answer the
following questions:

Q 3. What are the functions included in the Tesys U system?

Q 4. With the equipment at your disposal, indicate the name, reference and function of each
part.

With the help of the resource document “A4 - TeSys U_P_EN-Wiring.pdf”, draw on QElectrotech the
DOL 2 direction circuit.

Q 5. How many wires do you need to do the wiring?

Q 6. Is this integrated system will add advantages on the wiring to compare with the
traditional wiring?

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5. Task 3
Q 7. Complete your DOL 2D with Tesys U system diagram by adding the following pilot lamps:

 Forward direction – Yellow pilot lamp

 Reverse direction – Green pilot lamp
 Overload/Short Circuit – Red Pilot lamp.

Q 8. List all devices, equipment you need to perform the wiring of the DOL 2D with Tesys U
System.
Q 9. Collect your equipment and perform the wiring.
Q 10. With the Master trainer and according to the security standards, perform the
commissioning and test your equipment.
Q 11. If there is malfunction, find and repair the fault. Test again.

Don’t remove your equipment, you will use it for the next exercise

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Soft Starter
Code: TOT-M03-PA-006-TR_005_Ver-
TOT - Training of Trainer 00

Title: Soft Starter # 005

Module: M03 - M3-Building Installation Doc: TR - Trainee

Type of Activity: PA - Practical
Topic: 006 - Industrial wiring
Activity
Equipment: C03 - Industrial devices for wiring.

Main Objective cpt.3-1 - Drawing and electrical circuit according to the standards
cpt.3-3 - Implement electrical wiring according to the standards
cpt.3-4 - Select the equipment in order to design an electrical circuit
cpt.3-5 - Establish the list of required equipment in order to make the electrical wiring of a
building
cpt.3-7 - Perform the commissioning of electrical circuit
Objectives The trainee will be able to :

Duration: 1:0
resources: Docs
-
Standards :
-

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1. List of Equipment
 Wiring Bench
 Power supply
o Connectors blocs
o 1 MCB C10 4P and 1 RCD 30mA 4 P)
o 1 MCB C4
o 1 MCB C2
o 1 transformer 230-400V:24V
 Tool set
 Tesys U pack
o Power base LUB120
o Auxiliary contacts LUA1C20
o Auxiliary contacts LUFN11
o Control Unit LUCA05B
o Reverse bloc LU2MBOB
o Connector block LU9M1
o Pre-wiring block LU9MR1C
 Soft Starter Altisart ATS01N206QN
 Circuit Breaker GV2ME08
 1 Box 3 Push buttons XAL D311
 1 Box 8 holes for push buttons and pilot lamps XAP A2108
 2 Push Buttons with 1 NO and 1 NC each
 2 Push button with 1 NC
 1 push button 1 NO
 1 switch 1NO
 1 Pilot lamp Red
 1 pilot lamp Yellow
 1 pilot lamp Green
 Set of connectors
 Set of wires
 Set of number
 Computer + QElectrotech Software

Symbols:

Work to be performed Information / Tip

Teacher/Professor required Danger

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2. Preamble
The Direct on line starter for Induction Motor produces a huge demand of current. Usually the
starting current is 7 to 10 times the rating current of the motor. This situation can be an issue for
motor with large Power. To solve this issue, starters have been designed such as Star-Delta, Rotor or
Stator starters. The aim is to reduce the starting current.

The new power electronic components have allowed the design of “Electronic Starter”. The Altistart
is one of them. This device will help to control the starting current of the Induction Motor.

It is composed of dimer that will control the voltage across the motor coil and consequently the
current. But this as a drawback! The toque will be affected and the starting torque will be less than
the DOL one. To fix it, an initial voltage and a bust voltage can be controlled by the Altisart.

3. Task 1
By using the technical documents about the Altistart (DIA2ED2140603EN %28web%29.pdf and
ATS01_IS_ATS01N2_1624686_04.pdf) available on the Moodle platform, answer the following
questions:

Q 1. What are the functions of the 3 selector on the altistart?

Q 2. How can we control the start and Stop of the motor?
Q 3. What is the rating of the Altistart in your possession?

4. Taks 2
With the help of the documents above:

Q 4. Add on your previous wiring diagram the soft starter Altistart. The control of the starting
will be done directly by connecting the terminal “LI2” with the terminal “LI+” of the Altistart.
(You must use the previous wiring (DOL FR/RV with TeSys U system)
Q 5. After validation of the Master Trainer, apply the modifications to your wiring.
Q 6. Perform the commissioning and test your system.
Q 7. Are the start and Stop according to the time diagram given on the data instruction sheet?
(ATS01_IS_ATS01N2_1624686_04.pdf)
Q 8. By using an Oscilloscope and a voltmeter, Observe the voltage on the motor coil. Describe
the evolution of the voltage and the consequences on the motor functioning.

5. Task 3
Q 9. Modify your installation to control the start and stop of you motor by using a switch.
Q 10. Perform the commissioning and test your system.
Q 11. Are the start and Stop according to the time diagram given on the data instruction sheet?
(ATS01_IS_ATS01N2_1624686_04.pdf)

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6. Task 4
Q 12. Modify you wiring to control the Start and Stop with Push Buttons.
Q 13. Perform the commissioning and test your system.
Q 14. Are the start and Stop according to the time diagram given on the data instruction sheet?
(ATS01_IS_ATS01N2_1624686_04.pdf)
Q 15. Connect the “BOOST” input to the “LI+” terminal.
Q 16. Test your system.
Q 17. What is the effect of the “BOOST” Function?

Remove all wires and components from you mesh (Expect Power supply).
Clean you working place.

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Induction Motor controlled by VSD

Code: TOT-M03-PA-006-
TOT - Training of Trainer TR_0006_Ver-00

Title: Induction Motor controlled by VSD # 0006

Module: M03 - M3-Building Installation Doc: TR - Trainee

Type of Activity: PA - Practical
Topic: 006 - Industrial wiring
Activity
Equipment: C03 - Industrial devices for wiring.

Main Objective cpt.3-1 - Drawing and electrical circuit according to the standards
cpt.3-4 - Select the equipment in order to design an electrical circuit
cpt.3-7 - Perform the commissioning of electrical circuit
cpt.3-8 - Perform electrical measurement according to the safety and security rules
Objectives The trainee will be able to :
Cliquez ici pour taper du texte.
Duration: 5:0

resources: Docs
-
Standards :
-

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1. List of Equipment
 Wiring Bench
 Power supply
o Connectors blocs
o 1 MCB C10 4P and 1 RCD 30mA 4 P)
o 1 MCB C4
o 1 MCB C2
o 1 transformer 230-400V:24V
 Tool set
 1 Circuit Breaker GV2ME08
 1 Contactor LD09
 1 VSD Altivar 312
 1 Potentiometer
 1 Box 3 Push buttons XAL D311
 1 Box 8 holes for push buttons and pilot lamps XAP A2108
 1 Push Buttons with 1 NO
 1 Push Buttons with 1 NC
 1 Emergency Stop Button with 1 NC
 1 Selector Switch 3 position with 2 NO
 1 Pilot lamp Red
 1 pilot lamp Yellow
 1 pilot lamp Green
 Set of connectors
 Set of wires
 Set of number
 Computer + QElectrotech Software

Symbols:

Work to be performed Information / Tip

Teacher/Professor required Danger

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2. Preamble
To control the starting current of an Induction motor, we can us a soft starter, but if we want to
control more efficiently the starting and the running of the motor, we can use a “Variable Speed
Drive” or VSD.

You will perform in this activity the wiring and the configuration of a VSD to control the speed of an
induction motor.

3. Study of VSD
With the help of the documents

 “ATV312_Getting_Started_EN_S1A10942_04.pdf” page 2
 “ATV12_user_manual_EN.pdf”, pages 17 to 27

Q 1. Identify the name of the terminals used for the power supply and to connect the motor.
Q 2. Identify the inputs used to control the motor. (in 2 wires configuration)
a. What input control the Forward, the Reverse direction?
b. Those inputs will be controlled by Switch or Push button?
Q 3. Witch inputs control the speed reference?
a. With what component, the speed reference is setting up?
Q 4. What is the function of the terminal R1A, R1B, R1C?
Q 5. The supply of the VSD will be done with a “Watch Dog” circuit. A Watch Dog circuit is a
circuit that monitor the security of a system. The most common is a DOL style circuit. It
contains at least 1 Emergency Stop Button, a Start push button (Power Up), a Stop push
Button (Power down) and a contactor. The contact “VSD ready is placed in series with the
contactor’s memory contact. With the help of the previous questions, design the electrical
circuit to control an Induction Motor through a VSD with the following components:

 Q1: Main Circuit Breaker

 KM1: Watch Dog Contactor
 S0: Emergency Stop Button
 S1: Power down push button
 S2: Power up push button
 VSD: Variable Speed Driver ATV312
 S10: Turn Switch 3 positions (2 NO contacts) for Forward/Reverse control
 P1: 10 K potentiometer to control the speed reference.
 Connectors & terminals.

Q 6. After validation from the Master Trainer, collect the equipment and perform the wiring.
Q 7. Perform the commissioning of your wiring.

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4. VSD’s configuration
Q 8. With the help of the documents “ATV12_user_manual_EN.pdf”, page 45, describe the
procedure to reset the VSD to its factory settings (parameter set).
Q 9. Perform the factory parameter reset on your VSD.
Q 10. After a rest to factory setting, the VSD needs to be configured with our application.
a. With the help of the page 29, give the function of the following parameters: bFr, Uns,
LSP, HSP, Ith.
b. Adjust the parameter above to the application and motor.
Q 11. After agreement of the Master Trainer, perform the test and check that the motor’s speed
will follow the speed reference given by the potentiometer.
Q 12. What is the function of ACC and DEC parameter?
a. Verify your affirmation by testing different values.

5. Control by 3 Wires configuration.

Q 13. With the help of the previous document, modify the wiring of your installation to control
the VSD and its motor with the 3 Wires configuration.
Q 14. Lock up in the documentation the parameter to adjust to be able to control the VSD with
the 3 wires configuration.
Q 15. After agreement of the Master Trainer, test your system.

6. Measurements
Q 1. By using an oscilloscope and its probes (current and voltage), visualize the current and the
voltage across a motor coil.
a. What ids the shape of the current?
b. What is the effect off a torque change?
c. What is the shape of the voltage?
d. What is the effect of a speed reference change?
Q 2. Visualize the current and the voltage on the input power of the VSD.
a. What is the shape of the Voltage?
b. What is the shape of the current?
c. What is the effect of the torque change?

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IV. Annexes

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Annex Contents

ANNEXES AND RESOURCES ..........................................................................................................................IV-5

QELECTROTECH................................................................................................................................................... IV-5
IEC SYMBOLS............................................................................................................................. ......................... IV-5
ZELIO SOFT ............................................................................................................................. ............................ IV-5

ANNEXES FOR ELECTRICAL INSTALLATION ....................................................................................................IV-6

CONTACTOR ............................................................................................................................. .......................... IV-6

HOTEL DEVICES.................................................................................................................................................... IV-6
OCCUPANCY SENSOR ............................................................................................................................................ IV-6
POWER SUPPLY ............................................................................................................................. ...................... IV-6
SPD & SURGE ARRESTER ............................................................................................................................. ......... IV-6
ZELIO IV-6
LEVEL OF ILLUMINATION IN ROOMS: ........................................................................................................................ IV-6

ANNEXES FOR INDUSTRIAL INSTALLATION ...................................................................................................IV-7

INTEGRATED DEVICES - TESYS U............................................................................................................................ .. IV-7

METRE - POWER LOGIC ........................................................................................................................................ IV-7
SOFT STARTER - ALTISTART ............................................................................................................................. ....... IV-7
VSD - ALTIVAR ATV312 ...................................................................................................................................... IV-7
VSD - ALTIVAR ATV320 ...................................................................................................................................... IV-7

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Annexes and resources

Documents available on the Moodle Platform course “Resources module 3”

QElectrotech
1- https://qelectrotech.org/
2- http://download.tuxfamily.org/qet/joshua/html/QET.html

IEC Symbols
1- IEC60617 Symbols.pdf

Zelio Soft
1- Programming Guide-ZelioSoft2.pdf

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Annexes for Electrical Installation

Documents available on the Moodle Platform course “Resources module 3”

Contactor
1- Kontactor_Acti 9 iCT_A9C22715.pdf
2- Kontactor_Acti9 Contactor Din Katalog Indonesia.pdf
3- Kontactor_Contactor Din Instruction Sheet_ID.pdf

Hotel devices
1- Hotel devices wiring.pdf
2- Pieno_E8231BPDMW_WE.pdf
3- Pieno_E8231EKT_WE_G1.pdf
4- Pieno_E8231EKT_WE_G1.pdf

Occupancy sensor
1- CCT551011_CCT551012_HW_2016_38_EN.pdf

Power supply
1- ABL8REM24030_DATASHEET_ID_en-GB.pdf
2- DIA3ED2170401EN.pdf

SPD & Surge Arrester

1- SPD_998-6713_GMA-GB_A.pdf
2- SPD_16612_DATASHEET_ID_en-GB.pdf
3- SPD_M9DP77EN.pdf

Zelio
1- Smart Relay - Zelio Logic Catalog 2018.pdf
2- Smart Relay - Zelio Logic SR2_SR3_SR3B261BD.pdf
3- Smart Relay - Zelio Logic SR2_SR3_SR3B261BD-Instruction sheet.pdf
4- Programming Guide-ZelioSoft2.pdf

Level of Illumination in rooms:

1- ID Illumination.pdf

IV-6
| Confidential Property of ©CoE EARE
 [MODULE 3] | Annexes for Industrial Installation Annexes

Annexes for Industrial Installation

Documents available on the Moodle Platform course “Resources module 3”

Integrated devices - TeSys U

1- A4 - TeSys U_P_EN.pdf
2- A4 - TeSys U_P_EN-Wiring.pdf
3- TeSys U_1629984_01A55.pdf
4- TeSys U_1639084_01A55.pdf
5- TeSys U_163884301A05-10.pdf

Metre - Power Logic

1- Powerlogic 5560.pdf

Soft Starter - Altistart

1- ATS01_IS_ATS01N2_1624686_04.pdf
2- DIA2ED2140603EN %28web%29.pdf

VSD - Altivar ATV312

1- ATV12_user_manual_EN.pdf
2- ATV312 Installation bbv46391.pdf
3- ATV312_Getting_Started_EN_S1A10942_04.pdf
4- ATV312_programming_manual_EN_BBV46385_04.pdf
5- UM312_fr.pdf

VSD - Altivar ATV320

1- ATV320_ATV_Logic_Manual_EN_NVE71954_01.pdf
2- ATV320_Catalogue.pdf
3- ATV320_Getting_Started_EN_NVE21763_02.pdf
4- ATV320_installation_manual_EN_NVE41289_04.pdf
5- ATV320_Programming_Manual_EN_NVE41295_03.pdf
6- ATV320_Safety_Function_manual_EN_NVE50467_02.pdf

IV-7
Confidential Property of ©CoE EARE |
 INONESIAN - FRENCH – SCHNEIDER ELECTRIC
Centre of Excellence for
Electricity, Automation and Renewable Energy

@PPPPTK BMTI, Jalan Pesantren KM.2 Kel. Cibabat, Cimahi Utara, Cimahi 40513, Jawa Barat

Phone : +62 (0)22 665-2326 x142

In Partnership with :
THE MINISTRY OF EDUCATION – FRENCH REPUBLIC
THE MINISTRY OF EDUCATION AND CULTURE – REPUBLIC OF INDONESIA
SCHNEIDER ELECTRIC FOUNDATION
PT SCHNEIDER ELECTRIC INDONESIA