ELECTRICAL INDUSTRY

ELECTRICIAN CLASS: 1

 READ THE FOLLOWING AND MAKE SURE THAT YOU UNDERSTAND THE
INSTRUCTIONS, IF YOU NEED CLARIFICATION CHECK WITH TRADE TESTING
OFFICER OR THE EXAMINER:.
a) Print your name and ID number on all works
b) Do not write anything on the question paper.
c) Any candidate found cheating will be disqualified.
d) Do not energize the circuit without the authority from the trade testing office or examiner.

INFORMATION:
Marks will be given for the following:
a) Neatness
b) Safety
c) Workmanship
d) Fault findings
e) Time taken on the project

1. PROJECT:
SEQUENTIAL STARTING TWO MOTORS
TASK INSTRUCTIONS

 Draw a schematic diagram both control and power for the sequential starting of two motors with
the following operations:.
a) Motor 2(M2) should start running 4 seconds after Motor 1(M1).
b) If Motor 1 is stopped or trips, Motor 2 should stop.
c) Motor 2 must be prevented (Through Interlocks) from running while Motor 1 is being reverse 1.
d) Motor 1 runs in Star – Delta.
e) Use on timer for the Control circuit.
f) Lamps should be included to indicate.
i. The Motors are running (Two Indicators).
ii. M1 has tripped.
iii. Power is on.
The Circuits should wired as per your diagram.

2. PROJECT:
 Crusher and feed belts motors:.
A Mixer Feed Belt Motor runs first followed by a 30Hp Crusher Motor. The Crusher Motor is followed by a
Crusher Feed Motor which runs – automatically 5 minutes after Crusher. The Mixer Feed and Crusher are
manually operated. All the 3 Motors are stopped by one local stop button. A circuit for all the motors.

Draw and wire the Control and Power Circuit to satisfy the above conditions.
i. In the Circuit include an Indicator for each Motor to show the above conditions.
ii. Interlock the Motors to satisfy the conditions of the starting sequence.
iii. The Feed Belt Motor is Star Connected.
iv. The 30Hp Crusher Motor has a Star – Delta starter.

3. PROJECT:
TIME: 5 HOURS
DESCRIPTION:
 Three conveyer belts:.
Two Short Conveyor Belts alternate to feed a Long Conveyor Belt. Short Belt No. 1 feeds the Long Belt when it
is running in the Forward Direction.

Short Belt No. 2 feeds the Long Belt automatically 10 seconds late when it is being reversed. Long Belt and
Short Belt No.1 manually operated.

An Emergency stop button is incorporated in the Circuit to switch – off Belt and Short Belt No. Or Long Belt
and Short Belt No. 2 when there is need.

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The Long Belt Motor by an indicator its trip condition. The two Short Belts Motors should each show by
indicators when in run and stop condition.

The Long Belt Motor is Star Connected while the two Short belt Motors are Connected in Delta.

The Short Belt Motor should be interlocked so that one Motor runs at any one given time and only when the
Long Belt Motor is running.
Task 1 Draw the Control Circuit for Motors
Task 2 Draw the Power Circuit of Motors
Task 3 Order the required components
Task 4 Wire the Control and Power Circuits for Motors
Task 5 Fault find on 1 Control Circuit 2 fault
Power Circuit 1 fault

4. PROJECT:
TIME: 5 HOURS
DESCRIPTION
 Grinding mill and conveyor belt motor interlock:.
A Grinding Mill Motor is controlled by an automatic Star – Delta starter and is interlocked to a steel Belt
Conveyor. The Conveyor Motor is controlled by a Direct On Line Starter. The Steel Belt conveyor has a manual
start button for normal starting and another button for inching. This button is used when the belt is being
inspected or repaired. The steel belt conveyor should be started for normal mining only when the grinding mill
is in delta. The inching circuit should operate when the grinding mill is switched off.

Use a change – over – switch and interlocks to wire the circuits. The grinding mill should show by an indicator
when it is in delta. The steel belt conveyor should also show by an indicator when it is in normal running.

Task 1 Draw the Control Circuit for both Motors

Task 2 Draw the Power Circuit for both Motors
Task 3 Order the required components
Task 4 Wire the Control and Power Circuits for both Motors
Task 5 Fault find on (i) Control Circuit (2 faults)
(ii) Power Circuit (2 faults)

5. PROJECT:
 Situational type question:.
Draw a circuit with three electric motors A, B and C.
a) All the motors must operate with one start button.
b) They should stop at different times manually.
c) In the event of fault, they should stop suddenly and there must be a serve ringing continuously.
d) Indicate the pilot light on each electrician motor.
e) Remote switch must stop all the motors.
f) Give four applications of that circuit.
g) List six advantages of the circuit.

6. PROJECT
 Forward and Reverse Star – Delta which runs sequentially with M2:.
The conditions
i. If M1 is in Forward, M2 runs manually.
ii. If M1 is in Reverse M2 can not run.
iii. Both Motors is manually operated.
iv. M2 is Direct on Line (DOL).
v. Use of interlocks is incorporated.

7. PROJECT
 Sequential start and stop of three motors:
i. Order of sequential starting of three motors is M1, M2 and M3
ii. Order of sequential stopping of motors M3, M2 and M1

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QUSTION 1 BAG STACKER
A bag stacker runs in two directions and is interlocked to a conveyor drive which runs only when the stacker is
in forward direction.
The conveyor drive motor has a provision for starting and running independently when the bad stacker is off.

 The bag stacker to show by an indicator when it is in reverse.

 The conveyor belt should be stopped from running when the bag stacker is being reversed (use interlocks).
 Use interlocks to start up the conveyor when the bag stacker is running in forward direction of rotation.
 The conveyor to show by an indicator lamp when it is running.
 Wire the circuit as per your diagram.

DRAW THE CONTROL AND POWER CIRCUIT

WIRE THE CONTROL AND POWER CIRCUIT
*the circuit to be wired as per the drawn diagram.

QUSTION 2 FOUR MOTOR CRANE

Draw schematic diagrams (control & power) for a four motor crane.
The following operations should be included.
1. Long travel.

 Hoist or auxiliary can be operated

 The cross travel cannot be operated.
2. Cross travel.
 During cross travel, auxiliary or hoist should operate.
 The long travel cannot be operated.
3. Hoist operation.
 During hoist, the auxiliary cannot be operated.
 The cross travel can be operated.

DRAW THE CONTROL AND POWER CIRCUIT

WIRE THE CONTROL AND POWER CIRCUIT
*the circuit to be wired as per the drawn diagram.

QUSTION 3 CRUSHER AND FEED BELT MOTORS

The mixer feed belt motor runs first, followed by 30hp crusher motor. The crusher motor is followed by a
crusher feed motor which runs automatically 5 minutes after the crusher. The mixer feed and the crusher are
manually operated.

All the 3 motors are stopped by one local stop button, an emergency stop button is incorporated in circuit for all
motors.

In the circuit, an indicator for each motor to show run connections. Interlock the motors to satisfy the conditions
of the starting sequence.

DRAW THE CONTROL AND POWER CIRCUIT

WIRE THE CONTROL AND POWER CIRCUIT
*the circuit to be wired as per the drawn diagram.

QUSTION 4 THREE CONVEYOR BELTS

 2 short conveyor belts alternate to feed a long conveyor belt.
 Short belt 1 feed long belt when it is in the forward direction.
 Short belt 2 feed long belt automatically 10 seconds later after it is being reversed.
 Long belt and short belt 1 are manually operated.
 An emergency stop to be incorporated to switch off long belt and short belt motor 1 and short belt 2 when
needed.
 Long belt to show a trip by indicator lamp.
 Two short belt motors to show indicator when in run and stop condition.
 Long belt motor is star connected and two short belt are connected in delta.

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  Two short belt motors are interlocked such that one motor runs at a given time and only when long belt is
running.
DRAW THE CONTROL AND POWER CIRCUIT
WIRE THE CONTROL AND POWER CIRCUIT
*the circuit to be wired as per the drawn diagram.

QUSTION 5 SHORT SCREW AND ELEVATOR

A short screw feeds an elevator, elevator feeds a conveyor belt.

The motors are interlocked.
The elevator motor runs only when the conveyor is running and the short screw starts automatically one minute
later after the elevator motor has started.
The short screw motor runs when the elevator motor is switched on.

 The elevator motor control to include an inch and change over switch for normal and inch start.

 The elevator motor to be connected in delta (not star delta).

 All motors to include their running positions by means of indicators.

 The elevator to show by means of indicator its trip and off position.

 The short screw control circuit to include a manual start button that may be used in emergency when timer
fails.

 All motors to be stopped by one button

 The elevator and conveyor motor control circuits to include one emergency stop button.

DRAW THE CONTROL AND POWER CIRCUIT

WIRE THE CONTROL AND POWER CIRCUIT
*the circuit to be wired as per the drawn diagram.

QUSTION 6 SYSTEMATIC STARTING OF 2 MOTORS

 M2 should start 4 seconds after M1

 If M1 is stopped or trips, M2 should stop
 M2 should be prevented through interlocks from running while M1 is Bing reversed
 M1 is a 20hp motor.
 Use one timer for control circuit.
 Lamps to show power on, the motor are running and tripped.

DRAW THE CONTROL AND POWER CIRCUIT

WIRE THE CONTROL AND POWER CIRCUIT
*the circuit to be wired as per the drawn diagram.

QUSTION 7 GRINDING MILL AND CONVEYOR BELT MOTOR INTERLOCK

 A grinding mill motor is controlled by an automatic star delta starter and is interlocked to a steel belt
conveyor.
 The conveyor motor is controlled by a direct on line starter.
 The steel belt conveyor has a manual start button for normal starting and another button for inching.
 This button is used when the belt is being inspected or repaired.
 The steel belt conveyor should be started for normal running only when grinding mill is in delta.
 The inching circuit should operate when grinding moll is switched off.
 Use a change over switch to wire circuits.
 Grinding mill to show indicator in delta.
 Conveyor to show indicator when running.

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DRAW THE CONTROL AND POWER CIRCUIT
WIRE THE CONTROL AND POWER CIRCUIT
*the circuit to be wired as per the drawn diagram.

QUSTION 8

Three 5hp 380v conveyor motors are to be sequentially started.

Conveyor motor C is to run first then B then A.
If C develops a fault, all motors stops
If A develops a fault, only A stops.
A & B are started direct on line.
Motor C is star delta.
All motors can run independently using inching buttons for the purpose of maintenance.

DRAW THE CONTROL AND POWER CIRCUIT

WIRE THE CONTROL AND POWER CIRCUIT
*the circuit to be wired as per the drawn diagram.

QUSTION 9

A crusher uses hydraulic jacks for loading its rollers.

The crusher motor can run when the hydraulic oil pump is running.
If the oil pump trips, both of them trips.
The oil pump can continue running when the crusher trips or stopped.
The crusher motor changes from star to delta after 20 seconds.
The oil pump is direct on line delta.
Indicator lamps to show crusher and oil pump running.

DRAW THE CONTROL AND POWER CIRCUIT

WIRE THE CONTROL AND POWER CIRCUIT
*the circuit to be wired as per the drawn diagram.

QUSTION 10

2 pumps A & B are arranged in such that pump A feeds B on its discharge.
Pump A is started manually and B starts automatically 10 seconds later.
Pump B can be stopped manually and restarts after 10 seconds later if A is still running.
A has a provision of manual starting in case of the automatic system fails.
Pump B cannot start if A is out of service.
Pump A trips if B does not run on auto or manual after 20 seconds of starting.
Pump motor A is wired in star delta while B is direct on line delta.
If any one of the 2 pumps trips, both come out of service.
Indication lights to show the pump in service.

DRAW THE CONTROL AND POWER CIRCUIT

WIRE THE CONTROL AND POWER CIRCUIT
*the circuit to be wired as per the drawn diagram.

QUSTION 11

A system has 3 conveyor belts A, B & C.

Conveyor A feeds B, B feeds C.
The belts are manually started or stopped.
Conveyor C has to run for B to run & B has to run for A to run.
The three belts can be inched independently of each other for maintenance purposes. If any of the belts is
manually tripped locally, all belts stops. The motors are in star delta with 10 seconds delay on change over.

DRAW THE CONTROL AND POWER CIRCUIT, WIRE THE CONTROL AND POWER CIRCUIT

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 *the circuit to be wired as per the drawn diagram.

QUSTION 12

2 motors are arranged to operate automatically as long as their control and power circuits are supplied. Motor A
starts to run after 5 seconds of power supply establishment and stops after 30seconds. Motor B starts 5 seconds
of motor A stopping and the cycle continues with A restarting after5 seconds of B stopping. The motor continue
to run until supplies are cut. Both motors are in star delta with 15 seconds changeover delay. Indicator lamps to
show running motors.

DRAW THE CONTROL AND POWER CIRCUIT, WIRE THE CONTROL AND POWER CIRCUIT *the
circuit to be wired as per the drawn diagram.

QUSTION 13

 Sand is fed manually into the elevator. The elevator then feeds a conveyor belt that offloads into rail
wagons. Both motors are operated manually.
 The elevator motor to be connected in delta and runs only when the conveyor belt is on.
 The elevator motor control to include inching button and a change over switch for normal and inch starting.
 Both control circuits to include indicators for run/on
 The elevator to show by separate indicators its trip & off position.
 Both motors to be stopped by one stop button.
 Emergency stop buttons to be included for the elevator and conveyor motor.

DRAW THE CONTROL AND POWER CIRCUIT, WIRE THE CONTROL AND POWER CIRCUIT
*the circuit to be wired as per the drawn diagram.

QUSTION 14
A steel shaping machine with 15hp 380V 50Hz has 2 modes of operation. Local and Remote. When LOCAL is
selected, the motor is to run in the forward direction and indicates when in full speed. When REMOTE is
selected, the machine is to jog in both forward and reverse direction.
When remote is selected, the machine cannot start locally.

DRAW THE CONTROL AND POWER CIRCUIT

WIRE THE CONTROL AND POWER CIRCUIT
*the circuit to be wired as per the drawn diagram.

QUESTIONS

(1) A mine operation requires a following operation on one of its processing plant which uses a 3 phase 1kw
induction motor.
Specifications

Speed-1440 rpm, voltage- 400v,50Hz. on starting the motor runs in the forward direction for 15 seconds and
stops automatically, the motor is required to be idle (stopped not running) for 20 seconds to allow the motor to
be still. After 20 seconds the lapse (motor being still) it is required the motor runs in the reverse direction.

(a) Design power and control circuit

(b) List the correct size of materials to be used for this project
(c) Wire the circuits.

(2) A heavy concrete rolling is run by a drip proof 3 phase induction motor, which has the following
Specifications:
Voltage- 400v, power- 40kw, speed- 940rpm and slip 0.04
The following are to apply;

 At starting the above plant stated should run in the reverse direction for 20 seconds.
 After running 20 seconds in reverse direction it must stop automatically for 30 seconds for motor to be still.

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 Automatically after 30 seconds of motor being still (not running) it must run in the forward direction.
 Motor runs in the forward direction automatically without initiating any start button (i.e. no forward start
button).
 Motor should run in forward direction continuously until stop button is initiated.

(a) Draw power and control circuit.

(b) list the materials required
(c) wire the circuits

(3) Draw schematic diagram for sequential of 2 motors with the following starting operation.
Motor 2 starts 20 seconds after Motor 1, if either motors stops or is overloaded or develops a fault both motors
should stop.

Motor 2 is prevented through interlocks from running while motor 1 is being reversed. Motor 2 runs in star-
delta and Motor 1 in direct online forward and reverse.

Draw power and control circuit

(4) Waste matter is to be pumped from a pit using two 5kw, 380v, 12.4A, 3000rpm using sump pump motor
and float switches. Pump A runs when the pit is 40%- 100% full. Pump B runs when the same pit is 70%-
100%
(a) Draw power and control circuit.
(b) list the materials required
(c) wire the circuits

(5) A mixer motor runs first, then a crusher motor. A crusher motor is a 30 hp which runs on star-delta. The
crusher feeder motor then runs automatically after 5 minutes of a crusher motor. The mixture and the
crusher feeder motors are manually operated and are star connected. One stop will stop all the motors. One
emergency stop button incorporated to protect all the motors.
Draw both power and control circuit to satisfy above operation. Interlocks should be included so that the
operation of the motor is as stated.

(6) The water that supplies Randall farm is pumped into a reservoir tank 2m above ground surface. It has been
discovered that the water pressure in the water reticulation is low. This has resulted in some areas of the
farm not receiving water. It has also made it difficult to carry out irrigation in areas that are at long
distances from the reservoir. It has been suggested for irrigation purposes, a water pump must be used.
Requirements

 A 3HP motor is to be used for irrigation.

 The irrigation should be started both locally and remotely ( i.e. at the tank and from the farm house)
 The irrigation pump should shut down and not start when water in the tank is less than 40% full.
 An indicator panel should be installed to indicate:
Irrigation pump running
Low water level (when less than 40% full).

(7) Three conveyor motors are to be run sequentially and manually operated starting with motor C then Band
finally A. motor B and A should not run unless motor C is running and motor A should not run unless B
and C are running. If motor C develops an overload both motors should stop and if motor B develops an
overload motor Band A should stop and if motor A develops an overload only motor A should stop. All
motors run in DOL.

(8)On a printing machine, the load which contains sheets of paper is raised by a 3kw, 380v, 3-phase
8.2A motor for 10 seconds and then stops automatically. Upon stopping it engages a 35hp
Which pulls the sheets of paper from the load tray for 5 minutes then stops? Upon stopping it
Automatically engages the first 3kw, 380v, 3-phase motor to run again but now in the reverse
Direction until the machine is stopped. A provision should be made for momentary reversal of

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The machine in case of a paper jams on the belt being driven by 35hp motor. In case of an
Overload a pilot lamp should come on. Include remote switching and an emergency stop in your
circuit.

(9) In a manufacturing company, a conveyor belt is used to ferry quarry from a crushing machine to a storage
shade. A 25Hp, 3 phase induction motor is used to drive the belt. Before the belt is driven, a siren should sound
first for 5 seconds, then automatically the induction motor starts driving the belt. The motor then runs for 2
minutes and then stops automatically and de-energizing the whole circuit. A provision should be made for
momentary reversal of the belt in case of a jam occurring. An emergency stop is required in the circuit. Run
and Stop indicators should also be included in the circuit.

a) Draw the control and power circuit to satisfy the above conditions. (3 hours)
b) Prepare a list of materials needed for this project. (20 mins)
c) Mount the equipment and wire the circuit using your diagrams. (4 hours)

(10) You are required to wire the lighting circuit of an electric workshop which has four entrances. The lighting
circuit is controlled through a contactor. Draw the following circuit and wire according to the IEE regulations.

(11) A grinding mill is to be driven by an 11kw, 380V 3- phase electric motor. The electric motor is to be
reversed using an inch button when the mill jams. Prepare the power and control circuit for this particular mill.
 List down the correct size of materials for this project.
 Wire according to your circuit diagram.

(12) A sheet pressing machine has a hydraulic pump which is driven by a 1,5Kw, three phase induction motor.
The hydraulic pump-lubricates gears on the drives before the main drive is introduced, the main drive consists
of a gear box being driven by a 20Kw screen protected,415 volts, three phase induction motor.

 At starting the hydraulic pump runs.

 20 seconds after starting the hydraulic pump, the main drive should run automatically.
 When the main drive is running, a lamp is to be lit to indicate “press running”.
 When either the hydraulic pump or the main drive develops a fault, both motors should stop.
 The circuit is to also incorporate a remote emergency stop button at the control room.

Design schematic control and power circuit.

Mount components and wire as per your circuit design.

(13) An Ore crashing has three conveyors that move ore from ore pit to the crasher. The plant is arranged that
the conveyors are started and stopped sequentially so that overloading the conveyor is prevented. Ore should be
loaded on a conveyor that is moving not stationary hence the need to interlock them in the control circuits.

 The sequence for starting is 3 then 2 then 1. The sequence for stopping is 1then 2 then 3. If 3 trips 2 and 1
must stop automatically through interlocks if 2 trips, 3 can go without stopping. 1 cannot start without 2 and
3 already going. 2 cannot start without 3 already going.

(14) Draw an automatic sequential star delta starter to start two motors which have a starting difference of 20
seconds. Also incorporate a JOG switch to run the motors.

(15) A Plant setup in a mine requires that on pressing the start button for a certain extraction process bulbs all
rated at 80W, 220V must glow in the following sequence Bulb A is to glow for 10 seconds and is then switched
of automatically. At the first instant when bulb A comes off Bulb B must switch on automatically for 15 seconds
and then switch off automatically. Automatically at the instant when bulb B goes off, Bulb C must glow for 10
seconds and then switch off automatically at the same time a 3-Phase motor is required to run.

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The motor must run automatically when bulb C goes off. The motor for this project is rated at 750W and has its
windings arranged in star formation internally and operates at 415V, 50Hz and has a speed of 1200rpm.

Draw the control and power circuit for the project

(16) In a thermal power station a 20KW AC 3-phase motor is used to drive mechanical equipment on a plant.
When the operator starts a warning light switches on and the motor automatically runs. The motor is protected
against overload and under voltage.

Draw and wire the power and control diagram of the above.

(17) Draw a control and power diagram for sequential starting of motors with the following operators.

 Motor 2 should start 20 seconds later after Motor 1

 If either motor stops or is overloaded or if it develops any problem both motors should stop
 Motor 2 must be prevented through interlock from running while Motor 1 is being reversed

NB: Motor 1 runs on direct on line whilst Motor 2 runs in Star-Delta.

(18) Three 3-phase motors 380V are running conveyors and are started automatically and sequential.

 Motor 3 starts first followed by Motor 2 and lastly Motor 1

 If motor 2 develops a fault it affects motor 1 and both motors stop
 If motor 1 develops a fault only motor 1 is affected
 All motors run on direct on line
 The 3 motors run independently of each other by JOGGING/ INCHING.

Design the control and power circuits

(19) A grinding mill can run in forward and reverse direction when running in forward it will enable a conveyor
belt to be started independently. The conveyor is used to load bags of mealie meal from the grinding mill. The
method of starting the grinding mill is a star-delta and a conveyor uses direct on line. The grinding mill should
show when running in reverse by an indicator lamp. The conveyor has a change over switch which will enable
us to JOG, run the motor in order to position the bags. The conveyor should show when not being jogged.

Draw the control circuit to satisfy this.

(20) The water that supplies Rindai farm is pumped into a reservoir tank 2m above the ground surface. It has
been discovered that the water pressure in the water reticulation system for the farm is low. This has resulted in
some areas of the farm not receiving water. It has also made it difficult to carry out irrigation in areas that are at
a long distance from the reservoir. It has been suggested that for irrigation purposes, a water pump is to be used.

The user requirement specifications are as follows:

 A 4Hp motor is used for the borehole pump

 A 3Hp motor is used for the irrigation pump
 Borehole pump should start pumping when the tank is 80% full and shut off when the tank is 100% full.
 The irrigation pump should able to be started manually both locally and remotely (i.e. at the tank and from
the farm house).
 The irrigation pump should shut down and not start when water in the tank is less than 40% full.
 An indication panel should be installed to indicate.
Borehole running
Irrigation pump running

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 Low water level (when less than 40% full)

Draw control and power circuit.

(22) In a processing plant a crane is used to move goods to and from. A 2KW 3-phase induction motor is to be
started on direct on line forward reverse starter. In each direction 10 seconds before the motor starts running, a
siren is supposed to sound and stop after 10 seconds. As soon as the siren stops sounding the motor should start
running. i.e. the motor get to the extreme end in all directions some limit switches are supposed to stop the
crane.

Design the control and power circuits to suit the conditions.

(23) Two three phase motors 420V, 50Hz. Motor A runs for 8 second then stops automatically for 20 seconds
then starts again but now in reverse direction. As it starts Motor B also starts.

Draw the control and power circuit.

Wire according to IEE regulations.

(24) In a production plant two motors are used to crush coal. The three phase squirrel cage induction motor are
rated 2Kw each if you press the start button the first motor will start running in the forward direction and then
stops 10 seconds later the motor will remain stationary for another 10 seconds before it automatically starts in
the reverse direction the second motor will also start running in the forward direction.

According to IEE regulations design a control and power circuit to suit the above conditions.
Take not only one start and one stop button will be used

(25) Design circuit with two motors which start in automatic sequence. Motor 1 starts first and run for 15
seconds before Motor 2 starts running. Both motors should run for the next 30 seconds. After 30 seconds Motor
2 should reverse automatically while Motor1 would continue running in the forward direction.

(26) Draw and wire the control and power circuit of two motors which operate under the conditions given
below.

 At starting in forward direction both motors start and motor B only stops 10 seconds later leaving motor A
running.
 Both motors should stop in the event of a fault.
 Include indicator lamps for motor direction and for motor being faulty.

(26) A packaging conveyor belt can run in both directions. The motor is in DOL delta include indicator lamps to
show the direction of belt in motion.

(27) A pump draws water from a borehole into a tank. The pump is started and stopped manually when the tank
is full. The pump motor is in DOL star. Include an indicator lamp to show the pump is running.

(28) A hoist is used to load goods on a ledge. The hoist moves up or down only when the “raise” or ‘’lower’’
button is pressed. Include indicator lamp to show direction of motion and the stooped position. The hoist motor
is in delta.

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(29) A hoist runs in star when lowering and changes from star to delta after 5 seconds when lifting. Mechanical
brakes are automatically applied when the hoist stops or when electrical power supplies are disrupted. A ‘’Brake
Release’’ contactor releases brakes automatically when the hoist starts to move. Include a buzzer and indicator
lamps for raising and lowering.

(30) A crusher uses hydraulic jacks for loading its rollers .The crusher motor can run when the hydraulic oil
pump is running. If the oil pump trips both of them trip. The oil pump can continue running when the crusher
trips or is stopped. The crusher motor changes from star to delta after 20 seconds. The oil pump motor is in
DOL delta. Indicator lamps to show crusher and oil pump running.

(31) Two pumps A and B are arranged such that pump A feeds B on its discharge. Pump A is started manually
and B starts automatically 10 seconds later.
Pump B can be stopped manually and restarts after 10 seconds if A is still running it has a provision for manual
starting in case the automatic system fails. Pump B cannot run if A is out of service.
Pump A trips if B does not run on auto or manual after 20 seconds starting.
Pump motor A is wired in star-delta whilst B is direct on line. If any one of the two pumps trips both come out
of service.

(32) Two motors are arranged to operate automatically as long as their control and power circuit are supplied.
Motor A starts to run after 5 seconds of power supply establishment and stops after 30 seconds. Motor B starts 5
seconds of motor A stopping and runs for 30 seconds after which the cycle continues with a restarting after 5
seconds of B stopping. The motors continue to run until supplies are cut.
Both motors are in star-delta with 15 seconds change over time delay. Indicator lights to show the running
motor.

(33) A system has three conveyor belts A, B and C. Conveyor A feeds B and B feeds C. The belts are manually
started and stopped. Conveyor C has to run for B to run and B have to run for A to run.
The three belts can be inched independently of each other for maintenance purposes. If any one of the belt is
manually tripped locally all belts stop. The motors are in star-delta with a 10 seconds delay on change over.

(34) An industrial machine has 2 motors, a lubrication pump and a work piece turning motor. The pump is
controlled by a direct on line (DOL) forward and reverse starter. The work piece turning motor is controlled in
one direction by a star-delta starter. The work p[piece turning motor is automatically energized 10 seconds after
the direct on line motor runs in the clockwise direction only.

You are required to design and construct a starter circuit.

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(35) A machine for molding cups and pots operates with motors. Motor A is the oil pump, Motor B is the
molder and Motor C is the water sprayer. All the motors are direct on line.

 Motor A should run first before any other motor.

 Motor B should be able to run forward and reverse.
 Motor B should not reverse when Motor C is not running; Motor B should be stopped first before reversing.
 All motor to be started manually using start buttons.
 Use one stop button before stopping the machine.

Design control and power circuit that satisfies the above.

(36) A bag stacker runs in two directions and is interlocked to a conveyor drive which runs only when the bag
stacker is in forward direction.

 The conveyor belt motor 2 and the bag stacker motor 1 to show by means of an indicator when it is in
forward direction.
 The conveyor belt motor 2 not to run when motor 1 is reversed.
 Use interlocks to stop motor 2 only when motor 1 is in the forward direction.
 The conveyor drive to have a provision for starting and running independently when the bag stacker is off.
 The conveyor to show by an indicator when it’s on.

Draw the control and power circuit.

Wire according to the IEE regulations.

(37) A short screw feeds an elevator. The elevator feeds a conveyor belt. The motors are interlocked and the
elevator motor runs only when the conveyor motor is running and the short screw starts automatically one
minute later after elevator motor has been started. The short screw motor runs when the elevator motor is
switched on.

 The elevator motor to include an inching button and a change over switch for manual starting and inching.
 The elevator motor to be connected in delta.
 Show running position of motors by indicators and trips.
 The short screw circuit to include a manual start button that may be used in emergency when timer fails.
 All motors to be stopped by one push button.
 The elevator and conveyor motor to include the emergency stop button for each motor.

Draw and Wire the circuits above

(38) In a uranium thermal power generating plant, there is a mechanism that is driven by a 40Kw three phase
squirrel cage motor. The motor has a speed of 1450 r.p.m and operates at 50Hz, 400 volts.

 On starting the operation, a push button is initiated and a lamp (A) should be lit to warm up the control
room operator.
 The lamp (A) referred to above is to be lit for 10 seconds, and then goes of automatically.
 After 15 seconds has lapsed of the first lamp (A) being off, a second lamp (B) is lit for 5 seconds and there
after the mechanism is to be driven automatically.

Draw and Wire the circuit above

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(39) Two three phase induction squirrel cage motor are to run in sequential on direct on line, with motor one to
run first followed by motor two 10 seconds later. Whenever a motor develops a fault both motors must stop.
Both motors are connected in delta.

Draw and wire the diagram.

(40) Two three phase induction squirrel cage motor are to run in sequential on direct on line, with motor one to
run first followed by motor two 10 seconds later. A provision should be made that if motor two stars running
motor one should stop.

Draw and wire the diagram.

(41) An 18KW three phase squirrel cage induction motor is used an extractor fan in a carpenter workshop. The
motor runs at a speed of 1440rpm and operates from 415V, three phase supply. The motor runs continuously in
forward direction and stops 10 seconds later then runs in reverse direction.

(42) You have been given a task to install an electric motor for a printer and it should run in both directions.
Design a suitable power and control circuit for this task and wire according to your diagram. For this task you
are provided with a 7,5Hp three phase induction motor. In your circuit an emergency stop button should be in
included. Also include a run and stop indicator lamp in the circuit.

(43) In a bakery 3KW, 4 pole, 380V, three phase squirrel cage induction motor is used to drive a machine which
mixes flour. The motor runs for 5 minutes in the forward direction and stops for 5 seconds after 5 seconds the
motor is energized in reverse direction and runs for 5 minutes and then stops for 5 seconds and is reenergized in
the forward direction. Draw the control and power circuit and wire it.

(45) In an industrial set up a 35Hp 3 phase motor is used for paper processing. If the paper jams, the fault is
rectified by the use of a momentary switch in the reverse mode. A siren rings first for 5 minutes before the
machine engages itself. Design the control and power circuit.

(46) A carpentry workshop consists of two machines and one extractor fan. The fan motor must start before any
machine is started and must stop when the last machine is switched off. In the event of fan motor overload
protection operating, all machines most stop. Operation of the overload protection of a machine motor will
only stop that machine as the workshop processes are independent of each other. The fan motor runs on STAR-
DELTA. The machine motors are star connected. Draw the circuit diagrams.

(47) A 380v, 3 phase submersible pump being driven by a 2Hp motor is used to pump water to a feeder mixer
to supply the required volume of water the pump must run for 30 seconds and then stops thereby automatically
engaging the feeder mixer being driven by a 25Hp, 50Hz, 0,8pf by lag 3 phase cage rotor motor. The
requirements are that when the mixer jams or is overloaded the excess material is removed by reversing the
mixer momentarily. A warning signal is in the form of a siren is set 5 seconds before the machine starts

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operating. When the siren stops the machine should start automatically. Include an emergency stop in your
circuit which should stop everything. Run and Stop indicator lamp to be included. (2013)

(48)A 0.75KW; 380V; 3 phase electric motor runs in the forward direction for 10 seconds and stops
automatically. Upon stopping it engages a 22KW;380V; 3 phase motor that is star-delta started, it runs and after
10 minutes it automatically engages the first 0.75KW;380V; 3 phase motor to run again but now in the reverse
direction until the machine is stopped. A warning signal is sent 3 seconds before the machine starts. In case of
an overload a pilot light comes ON. Main and Delta uses 380V coil.

(49) The conveyors are used to transport quarry from point A to point B at quarry mine. The conveyors are
driven by 3 phase; 380V electric motor. Motor A which is driven by a 2.2KW starts first followed by motor B
which also driven by 1.5KW; 380v; 3 phase motor. Motor C runs last and is driven by a 0.75KW; 380V; 3 phase
motor. All motors are connected on DOL start. If motor A stops all motors should stop, if motor C stops, no
motor should stop and if motor B stops, motor C stops. Draw control and power circuits.

(50) A 3 phase, 380V; 50Hz; 2Hp submersible pump is used to pump water into the feed mixer for 2 minutes
and stops. The feed mixer is coupled to 3 phase; 380V;50Hz; 25Hp induction squirrel cage motor which is
automatically engaged and runs for 5 minutes and automatically stops. If an overload occurs the feed mixer is
momentarily and manually reversed. A warning signal should sound 10 seconds before the machine starts

 warning signal, start and run indication lamps are 220V*

 only start contactor for 25Hp motor is a 220V coil contactor*
 Draw a control and a power circuit diagrams

(51) At a mining concerns, a 2Hp;380v;3 phase induction motor runs in the forward direction for 10 seconds
and stops automatically .A siren immediately comes ON for 5 seconds before engaging a 30Hp;380v;3 phase
electric motor that is star-delta run. It runs for 15 minutes, stops automatically and switches ON the first 2Hp;
380v; 3 phase induction motor but this time in the opposite direction until the machine is stopped. Draw a
control and power circuit diagrams

(52) A 50Hp; 380v; 3 phase induction motor is used to drive a vacuum pump. A warning signal should be sent 5
seconds before the machine starts automatically. A conveyor belt should switch ON automatically 20 seconds
after vacuum pump to dry bed. The conveyor belt should also send a warning signal 3seconds before starting. A
conveyor belt is driven by a 7.5hp; 380v; 3phase induction motor.

Using correct symbols, design and wire control and power circuit for suitable situation.

(53) A 20Hp; 380v; 3 phase induction motor is running a hoist under the following conditions:

 In forward direction when the start button is pressed, a siren comes first for 5 seconds before the motor start
running
 In reverse direction, the motor runs only when the start button is pressed.
 When it get depressed the motor automatically stops

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Draw control and power circuits to suit the required conditions

(54) A 30Hp; 380v; 3 phase induction motor is used to drive a pump situated a kilometer away from the tank
house. When the tank is at low level the pump get energized automatically. When the tank is full the pump gets
de-energized automatically. When the tank is at low level, a warning siren is given before the get energized
automatically. Show by indicator lamp the pump trips. Draw control and power circuits using correct symbols.

(55) An electrical plant consist of a 50Hp;380v;3 phase induction motor run water pump which can be started or
stopped locally or by remote control.

Include the following:

 an audio alarm for motor trips

 indicator lamp to show the motor being stopped or running
 Draw a control and power circuits

(56) A 40Hp; 380v; 3 phase induction motor is assisted by a 7.5Hp; 380v; 3 phase induction motor, only when
running in forward direction. When it is running in reverse direction it sorely runs. Draw control and power
circuits using correct symbols

(57) A bag stacker runs in 2 directions and is interlocked to a conveyor drive which runs only when the bag
stacker is in forward direction. The conveyor drive motor has a position for starting and stopping independently
when the bag stacker is off. Draw control and power circuits

(58) A crushing mill is to be driven by a 15Hp; 380v; 50Hz; 3 phase squirrel cage induction motor. The mill is
fed by star connected 2.5kw; 380v; 50Hz; 3 phase cage motor. The mill motor is to be reversed using an inch
button when the mill jams. The conveyor should not run when the mill motor is inching. Prepare power and
control circuits.

(59) A conveyor belt is used to ferry quarry. It is driven by 25Hp; 380v; 3 phase induction motor. A siren should
be sent for 5 seconds and engages a conveyor belt automatically. A provision for emergency stop. Run, stop
indication lamp to be included. In case of a jam it is momentarily reversed. Draw power and control circuit

(60) In a manufacturing company a conveyor belt is used to ferry quarry from a crashing machine to a storage
shade. A 25Hp; 380v; 3 phase induction motor is used to drive the belt. Before the belt is driven a siren should
sound first for 9 seconds then automatically the induction motor starts driving the belt. The motor runs for 2
minutes and then stops automatically. A provision should be made for momentary reversal of the belt in case of
jams occurring. An emergency stop is required in the circuit. Run and stop indicator should also be included in
the circuit. Draw control and power circuit.

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(61) A grinding mill is to be driven by an 11kw, 380V 3 phase electric motor and is fed by a conveyor driven by
a 3kw electric motor. The mill motor is to be reversed using an inch button when the mill jams and is protected
by thermistors. The conveyor should not run when the mill inching. Prepare the power percentage control circuit
for this particular mill.

(62) A grinding mill is controlled by an automatic star delta starter and interlocked to steel conveyor belt. The
conveyor belt is controlled by a D.O.L starter for a normal starting and another button is used for normal starting
and another button is used when inching. When this is being inspected or repaired the steel should be started for
normal running only when the grinding mill is switched off. Grinding mill should show by indicating when it is
in delta. Steel belt should indicate when running normal.

(63) A mine hoist is to be wired in such a way that upon raising to the surface it must overshoot to the headgear
direction. It should allow movement only in the direction opposite to that it had before. Tripping indicators for
power ON up direction and down direction and overload trip to be indicated.

(64) Two short conveyor belts alternate to feed a long conveyor belt. Short belt number 1 feeds a long belt when
it is running in the forward direction. Short belt number 2 feeds long belt automatically 10 minutes later when it
is reversed. Long belt and short belt number 1 are manually operated. An emergency stop button is in the circuit
to switch OFF long and short belt number 1 or long and short belt number 2 when they are need. The long belt
should allow an indicator its trip condition. The long belt motor is star connected while the number 1 and 2
(short conveyor belts) motor are star delta connected the two short belt motors must not run at the same time and
should run only when long belt motor is running.

(65) The market garden section consists of major sections. The vegetable and the grain section, for watering the
garden water is pumped from a reservoir tank using two 10kw, 380V 50HZ 3 phase induction motor controlled
by a float switches. Watering starts when the tank is 100% full. When the water level drops to 75% the
vegetable would have been watered adequately hence the pump watering that section stops. The pump watering
the grain section continues and stops when the water level has fallen to 10%.

(66) The stock feed processing plant consist of grain crushing mill which is to be driven by a 15kw, 380V,
50HZ 3 phase induction motor. The grain is fed into the mill by a conveyor belt system which is supported to a
3kw, 380V; 50HZ 3 phase induction motor. The conveyor runs ON when the mill is operating at full speed. The
mill jams occasionally during operation hence a circuit should be provided for the mill to clear the system.

(67) The garage section has two projects the compressor and the pillar drilling machine. The condition for
operation for the compressor are as follows, the air compressor is driven by a 20Hp motor which is connected to
380V, 50Hz, 3phase supply. Before the compressor can be started a water pump and air pump must be started in
order to supply coolant to the compressor. If the water pump fails, the compressor motor must stop also does the
air pump failure. The compression motor is protected against high pressure and high temperature conditions.
There is also a blower which cools the compressed air before it gets into air receivers.

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(68) A water pump driven by 30Hp motor is cooled by external fan of 3Hp motor which switches ON when the
machine attains its full speed. Under normal situation, when the water level goes below the required level, the
machine will switch ON automatically and takes one hour to fill the tank to the maximum level and it will
automatically switch off for the maintenance sake, the machine can be started and stopped locally despite the
water levels and the machine cannot be started remotely during maintenance. In case of automation failure the
machine can start and stop manually on remote.

(69) An air compressor is driven by 20HP motor which is connected to a 550V supply and driven by a 22A.
Before the compressor motor can be started, a water pump and oil pump must be started to supply the coolant
for the compressor. If the oil pump fails the compressor must trip out as the same it does if the water pump fails
the conveyor is also protected against high pressure and high temperature condition. The power cct conditions
are D.O.L draw a control cct that include the protection and interlock mentioned above.

(70) A lathe is driven by a 7Hp, 380V motor before the motor is started a water pump and oil pump is started
first to supply lubrication to the lathe if the water pump and oil pump fails the lathe must trip out. The lathe
motor is protected against high temperature conditions among usual protections.

Draw the control and power cct for the project.

(71) A 12Hp 16,5A, 380V is to run a high pressure reservoir pump, the water level in the reservoir must not fall
below ⅟4 full and must not overspill. Pump must operate below 4 bars pressure upon starting in the automatic
and manual the siren must sound for at least 20 seconds to alert and allow the pump attendant to operate safe
valve for safety for protection against accommodation of moisture, the starter must not run if the panel door is
open. An indicator must show pump in run and in stop mode. Overload trip condition must by way of a light and
siren however upon acknowledgement trip on overload. A button must cancel the siren but the light induction
ON until reset remote switching room a plan to an away from starter must be enabled. An energy
ammeter/voltmeter must be incorporated.

Design cct

(72) Two separate pumps A and B 7,5HP 380V 12,6A are controlled by 2 separate float switches A and B float
A runs at 40% full of float and takes over at 75% if the refuse tank is filling fast float B stops pump B when the
tank is below 75% full and float A stops pump when the tank is 40% full. Design the power and control cct.

(73) A 90Hp motor is to drive a milling crusher when it is running it is indicated by a green light. However it
has a provision of itching inverse when it joins. It incorporates a conveyor belt when it is running and when it
stops the conveyor belt stops automatically.

Design a power cct, a control.

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(74) Design a cct that has local and remote control system. The local runs the cct continuously and remote is
used for jog. The local control runs the cct in both directions so as the remote. When the local controls are ON
the remote should not come in so as the remote when it is in the local should not come in. Design a control cct to
meet the above.

(75) A15HP machine motor is to be run in the forward when controlled locally and must indicate when in full
speed. It is also to jog in the forward and reverse direction when controlled in remote, when controlled in remote
it should not start locally. A light must indicate when motor is in full speed forward direction. Design power and
control.

(76) Design a cct that runs continuously or normal running in forward and jog in reverse. When normal running
at its full speed, the provision should be provided to allow the feeder conveyor belt into motion, the conveyor
belt must have a separate start or stop switch. When the main cct trips the whole cct should stop but when the
conveyor belt stops, the main cct continue running. When the cct is reversed, the conveyor belt should not come
in. Design the cct above.

NOTES

[A]CIRCUIT PROTECTION

What are the protective devices in a circuit?

1. MCB 2. Overload 3. Start-Stop button 4.Contactor 5.Interlocks 6. Emergency stop button

How do they offer protection?

1. MCB- protects against over current/excess current caused by short circuits, single phasing and sustained
surges.

2. Overload-protect against over current/excess current caused by excess load or single phasing

3. Start-stop button- if a circuit is interrupted no starting unless pressing start button. There is no automatic
restarting. There is an E-Stop in case of emergency.

4.Interlocks- avoiding simultaneous energization of coils and hence avoiding short circuits due to interchanged
of phases of the Forward and Reverse contactors. Dead short circuits on power circuit if the delta contactor
energized whilst star contactor is energized.

[B]CORRECT COMPONENTS

Correct overload positioning and setting.

DOL-Overload should be set at full load current since line current flows through the overload.

STAR-DELTA- overload should be set in the delta loop where 58% of full load current rating is found.

Full load current is obtained at the name plate of the motor.

For example, given 25Hp; 50Hz; 380v; 0.8 lagging

1Hp=0.746kw (all 10Hp motors and above STAR-DELTA)

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1Hp=746w

25Hp=22kw

P=√ 3.line voltage*line current*Cos α

1kw = 1 000w (e. g 33kw motor is equal to how many Hp [33 * 1000=33 000 ; 33 000 ÷ 746 =44.2Hp])

Contactor size

Switch gear- current rating- Threshold current or continuous current

 know the size of the contactor before installing it

Timer Setting

Changeover from star to delta ranges from 6 to 10 seconds

Why? It is where the transient rising starting currents are over

Transient rising starting current should drop up to a steady state value

Effects of improper timer setting

 Arcing of contacts due to making and breaking high starting current

[C]CORRECT OPERATION

[D] IDENTIFY AND RECTIFY FAULTS

[E]USE OF INSTRUMENTS AND TOOLS

[F] INTERPRETATION OF TESTS RESULTS

[G] SAFETY AND REGULATIONS

 ISOLATOR-Isolating
 OVERLOAD-Every motor exceeding 0,37kw mast incorporate with means of protection against overload.
 START&STOP-prevent auto restarting

-means of restarting and stopping

 CABLE- must withstand starting , acceleration and full load current

 COIL&HOLD IN-under voltage

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