GURU TEGH BAHADUR INSTITUTE

OF TECHNOLOGY
(Guru Gobind Singh Indraprastha University)



SUMMER INTERNSHIP REPORT
Undertaken at


CONTROL AND SWITCHGEAR ELECTRIC LTD

IN
RELAYS (MAGNETIC SWITCH)



BY:

DEEPAK VYAS
07113204911
EEE(5
TH
SEM)
















ACKNOWLEDGEMENT



I hereby take this opportunity to thank all those people whose knowledge and experience
helped me to bring this report in its present form. It would have been a tough task for me to
complete report without their help.

I express my sincere thanks and gratitude to My mentor and Mr. LAL BAHADUR and
Mrs. HIMANI GUPTA for providing me the opportunity to pursue my training at the
institution.

I would like to express my gratitude to my teachers for helping me in every aspect during the
training phase as well as in carrying out the whole project.

Finally I would like to express my deep appreciation to my family and friends who have been
a constant source of inspiration. I am internally grateful to them for always encouraging me
wherever and whenever I needed them.





DEEPAK VYAS
07113204911








COMPANY PROFILE


ABOUT C&S ELECTRIC LTD

C&S Electric Ltd. is amongst the leading suppliers of electrical equipment in India and is
Indias largest exporter of industrial switchgear. Its wide range of electrical and electronic
products find application in power generation, distribution, control, protection and final
consumption. C&S Electric is amongst the top 4 players in the LV switchgear business & the
market leader in the Power Busbar Business. In addition the company also has product
offerings for MV switchgear, Energy Efficient Lighting solutions and Diesel Generating Sets.
C&S Electric along with Solar EPC business, also has an electrical contracting business
which performs turnkey solutions for industrial and commercial electrification, substations
and power plants. C&S Electric was also the 2nd company in India to design and execute a
grid connected solar PV power plant in India.

HISTORY

1966 R N Khanna returns to India after spending 4 years
with FANAL as a switchgear design engineer.
Controls & Switchgear Company is founded in a
garage by R N Khanna, who is soon joined by his
younger brother Ashok Khanna (IIT Madras).

1966
-
1982
The company goes on to become amongst the
largest LV switchboards manufacturer in India,
executing prestigious and challenging jobs. Enters
Busduct business, with technology from Simelectro
France, to build on its strong relationships with
power generation utilities.
1982
-
1985
In a short time enters the switchgear components
business by technology transfer from Terasaki Japan
(Air Circuit Breakers); ABB Stromberg Finland
(Switches and Switch Fuse Units) and France
(Contactors, Overload Relays and Motor Starters).
Thus becomes a major LV Switchgear Player.
1992
-
1994
Diversities with 3 joint ventures: Wago (Terminals),
RS (Mail Orders) and AVK-SEG (Alternator and
Relays until 2004 restructuring).
1998
-
2007
Second Generation join the business. Big thrust on exports. Entry into Lighting and
Wiring Accessories. Establishment of EOU and SEZ facilities. Acknowledged as
Indias #1 Busbar Company. Growth of almost 40% for three years in a row 2005 to




2008. JV with Himoinsa of Spain to manufacture Diesel Generating Sets.
2008 Enters Medium Voltage business through a JV with Efacec of Portugal. Raises
private equity from GE Commercial Finance with intention to grow even more
aggressively through organic and inorganic means. Merges three main companies
into a single entity C&S Electric Ltd.

SEGMENTS
The business operations of C&S Electric are divided in the following strategic business units
(SBUs)
LV Switchgear SBU
Electronics SBU
Power Busbar SBU
Lighting & Wiring Accessories SBU
Electrical EPC SBU
Solar EPC SBU
C&S employs over 4000 people including 400 engineers, and has 17 state-of-the art
manufacturing plants in India, Belgium & China. It has 20 sales/marketing offices across
India and its products are exported to 80 countries. C&S Electric also has several joint
venture companies.

AWARDS

C&S Electric Ltd - Wins Solar Award
The Honble Minister for New & Renewable Energy Dr. Farooq Abdullah awarded C&S
Electric Ltd. for its 1 MWp Solar PV Power Plant at Village NANDHA, District Bhiwani,
Haryana being the 2nd PV Power Plant to get commissioned in India under MNRE
RPSSGP Program. The award comprises of a Trophy and a Certificate Of Appreciation and
was handed over on 25th September 2013 at the Scope Convention Centre, New Delhi.






INTRODUCTION TO RELAY


A relay is an electrically operated switch. Many relays use an electromagnet to operate a
switching mechanism mechanically, but other operating principles are also used. Relays are
used where it is necessary to control a circuit by a low-power signal (with complete electrical
isolation between control and controlled circuits), or where several circuits must be
controlled by one signal. The first relays were used in long distance telegraph circuits,
repeating the signal coming in from one circuit and re-transmitting it to another. Relays were
used extensively in telephone exchanges and early computers to perform logical operations.
A type of relay that can handle the high power required to directly control an electric
motor or other loads is called a contactor. Solid-state relays control power circuits with
no moving parts, instead using a semiconductor device to perform switching. Relays with
calibrated operating characteristics and sometimes multiple operating coils are used to protect
electrical circuits from overload or faults; in modern electric power systems these functions
are performed by digital instruments still called "protective relays".












Automotive-style miniature relay, dust cover is taken off





Relays are used throughout the automobile. Relays which come in assorted sizes, ratings, and
applications, are used as remote control switches. A typical vehicle can have 20 relays or
more














OPERATION OF RELAYS


All relays operate using the same basic principle. Our example will use a commonly
used 4 - pin relay. Relays have two circuits: A control circuit (shown in GREEN) and a load
circuit (shown in RED). The control circuit has a small control coil while the load circuit has
a switch. The coil controls the operation of the switch.




RELAY ENERGIZED (ON)
Current flowing through the control circuit coil (pins 1 and 3) creates a small magnetic field
which causes the switch to close, pins 2 and 4. The switch, which is part of the load circuit, is
used to control an electrical circuit that may connect to it. Current now flows through pins 2
and 4 shown in RED, when the relay is energized.







RELAY DE-ENERGIZED (OFF)

When current stops flowing through the control circuit, pins 1 and 3, the relay becomes de-
energized. Without the magnetic field, the switch opens and current is prevented from
flowing through pins 2 and 4. The relay is now OFF.




RELAY OPERATION

When no voltage is applied to pin 1, there is no current flow through the coil. No current
means no magnetic field is developed, and the switch is open. When voltage is supplied to
pin 1, current flow though the coil creates the magnetic field needed to close the switch
allowing continuity between pins 2 and 4.








BASIC DESIGN


A simple electromagnetic relay consists of a coil of wire wrapped around a soft iron core, an
iron yoke which provides a low reluctance path for magnetic flux, a movable iron armature,
and one or more sets of contacts (there are two in the relay pictured). The armature is hinged
to the yoke and mechanically linked to one or more sets of moving contacts. It is held in
place by a spring so that when the relay is de-energized there is an air gap in the magnetic
circuit. In this condition, one of the two sets of contacts in the relay pictured is closed, and
the other set is open. Other relays may have more or fewer sets of contacts depending on their
function. The relay in the picture also has a wire connecting the armature to the yoke. This
ensures continuity of the circuit between the moving contacts on the armature, and the circuit
track on the printed circuit board (PCB) via the yoke, which is soldered to the PCB.
When an electric current is passed through the coil it generates a magnetic field that activates
the armature, and the consequent movement of the movable contact(s) either makes or breaks
(depending upon construction) a connection with a fixed contact. If the set of contacts was
closed when the relay was de-energized, then the movement opens the contacts and breaks
the connection, and vice versa if the contacts were open. When the current to the coil is
switched off, the armature is returned by a force, approximately half as strong as the
magnetic force, to its relaxed position. Usually this force is provided by a spring, but gravity
is also used commonly in industrial motor starters. Most relays are manufactured to operate
quickly. In a low-voltage application this reduces noise; in a high voltage or current
application it reduces arcing.




A SIMPLE ELECTROMAGNETIC RELAYS






When the coil is energized with direct current, a diode is often placed across the coil to
dissipate the energy from the collapsing magnetic field at deactivation, which would
otherwise generate a voltage spike dangerous to semiconductor circuit components. Some
automotive relays include a diode inside the relay case. Alternatively, a contact protection
network consisting of a capacitor and resistor in series (snubber circuit) may absorb the
surge. If the coil is designed to be energized with alternating current (AC), a small copper
"shading ring" can be crimped to the end of the solenoid, creating a small out-of-phase
current which increases the minimum pull on the armature during the AC cycle.
[1]

A solid-state relay uses a thyristor or other solid-state switching device, activated by the
control signal, to switch the controlled load, instead of a solenoid. An optocoupler (a light-
emitting diode (LED) coupled with a photo transistor) can be used to isolate control and
controlled circuits.


NORMALLY DESIGN ID

Relays are either Normally Open or Normally Closed. Notice the position of the switches in
the two relays shown below. Normally open relays have a switch that remains open until
energized (ON) while normally closed relays are closed until energized. Relays are always
shown in the de-energized position (no current flowing through the control circuit - OFF).
Normally open relays are the most common in vehicles; however either can be use in
automotive applications.


Normally Open (NO)


Normally Closed (NC)






NORMALLY CLOSED RELAYS

The operation of a Normally Closed relay is the same to that of a Normally Open relay,
except backwards. In other words, when the relay control coil is NOT energized, the relay
switch contacts are closed, completing the circuit through pins 2 and 4. When the control coil
is energized, the relay switch contacts opens, which breaks the circuit open and no continuity
exists between pins 2 and 4.

DE - ENERGIZED (OFF)


ENERGIZED (ON)

















ACTUAL RELAY DESIGN

Current flows through the control coil, which is wrapped around an iron core. The iron core
intensifies the magnetic field. The magnetic field attracts the upper contact arm and pulls it
down, closing the contacts and allowing power from the power source to go to the load.











ISO STANDARDISED RELAY

ISO relays were designed to try and standardize relay connections, making it easier to test
and design systems. ISO relays are currently used by almost all automotive manufacturers
today. Both 4 and 5 pin designs are used in both standard mini and micro sizes. FYI: ISO is
short for International Standard Organization.









RELAY VARIATIONS
Other relay variations include three and five pin relays. A 3-PIN relay instead of two B+
input sources, this relay has one B+ input at pin 1. Current splits inside the relay, supplying
power to both the control and load circuits. A 5-PIN relay has a single control circuit, but two
separate current paths for the switch: One when the relay is de-energized (OFF - no current
through the control coil) and the other the energized (ON - current is flowing through the
control coil). When the 5-PIN relay is de-energized (OFF), pins 4 and 5 have continuity.
When the relay is energized (ON), pins 3 and 5 have continuity.

3 - PIN

4 - PIN

5 - PIN




STANDARD MINI ISO RELAYS TYPES
Below are two popular standard MINI ISO relay configurations. The size of a ISO Standard
MINI relay is a 1" square cube. Both 4 and 5 pins designs are used.



5 PIN
MINI RELAY





4 PIN
MINI RELAY





ISO MICRO RELAY TYPES

Below are two popular MICRO ISO relay configurations. The size of a ISO MICRO relay is
a 1" x 1" x 1/2" square (1/2 as thick as a Mini relay). Both 4 and 5 pins designs are used.
5 PIN
MICRO RELAY









CIRCUIT IDENTIFICATION

Relays are easy to test but often misunderstood. Using a 4 pin relay for our example, we
must first identify the pins. Some manufacturers place a diagram and pin ID on the
outside of the relay case to show which pins are part of the control circuit and which pins
are part of the load circuit.












CONTINUITY CHECK FOR PIN ID

If the relay is not labeled, use an ohmmeter and check to see which pins are connected to
each other. You should typically find an ohm value of approximately 50 to 120 ohms
between two of the pins. This is the control circuit. If the coil is less that 50 ohms it could be
suspect. Refer to manual to verify reading. The remaining two pins should read OL (infinite)
if it's a normally open relay, or 0 ohms (continuity) if it's a normally closed relay. If the
readings are correct, proceed to the next test. Note: If none of the relay pins showed a coil
value and all pins show OL or 0 ohms, the control coil is damaged and should be replaced.












TESTING OF RELAYS


PRACTICAL TESTING

Once the pins have been identified, energize the control circuit by supplying B+ to pin 1 and a
ground to pin 3. A faint "click" will be heard; although this "click" means the switch has moved
(closed), it does not mean the relay is good. The load circuit switch contacts could still be faulty
(high resistance), and further testing is required. A common mistake technicians make is they
hear a "click" and assume the relay is good. Take the extra step and verify operation.





CAUTION
Testing relays with built in clamping diodes require a special procedure. These relays are
polarity sensitive; placing B+ to the wrong pin (backwards) while performing a practical test
will forward bias the diode and damage the diode, thus destroying the protective quality of the
diode.









OPERATIONAL CHECK WITH TESTLIGHT

Now start the second part of the test. Energize the relay (control side) by supplying B+ to pin
1 and a ground to pin 3. A click should be heard. With the relay still energized, supply B+ pin
2 of the load circuit. The test light will be on. De-energize (remove B+) the control circuit at
pin 1; the test light at pin 4 should go off. A test light is preferred because a test light will
draw current through the switch.





CAUTION
Testing relays with built in clamping diodes require a special procedure. These relays are
polarity sensitive; placing B+ to the wrong pin (backwards) while performing a practical test
will forward bias the diode and damage the diode, thus destroying the protective quality of
the diode.






OPERATIONAL CHECK WITH VOLTMETER

A voltmeter can be substituted in place of a test light; however be aware if the contacts are
partially burned, the voltmeter will show voltage indicating good contact even when bad.
Remember high impedance digital voltmeters draw almost no current. Energize the relay
(control side) by supplying B+ to pin 1 and a ground to pin 3. A click should be heard. With
the relay still energized supply B+ to pin 2 of the load circuit. Connect the RED lead to pin 4
and the BLACK lead to ground. The voltmeter will indicate source voltage (12V). De-energize
(remove B+) the control circuit at pin 1; the voltmeter should now read "zero". Re-energize the
relay and the voltmeter should return to 12 volts.





CAUTION
Testing relays with built in clamping diodes require a special procedure. These relays are
polarity sensitive; placing B+ to the wrong pin (backwards) while performing a practical test
will forward bias the diode and damage the diode, thus destroying the protective quality of the
diode.








OPERATIONAL CHECK WITH AN OHMMETER

An ohmmeter can also be used to test the load circuit, but the same problem as the voltmeter
comes into play. Energize the relay (control side). Supply B+ to pin 1 and a ground (neg.) to
pin 3. A click should be heard. Place the leads on an ohmmeter to across pin 2 and pin 4.
Assuming it is a normally open relay the ohmmeter will indicate a complete circuit (close to
zero -0 ohms). De-energize the control circuit at pin 1(remove B+). The ohmmeter should
indicate OL (an open circuit - infinite). Re-energize the relay and the ohmmeter should return
to "zero" ohms. Note: some manufactures provide a maximum ohm value when the switch
contacts are closed, example 5 ohms max.



CAUTION
Testing relays with built in clamping diodes require a special procedure. These relays are
polarity sensitive; placing B+ to the wrong pin (backwards) while performing a practical test
will forward bias the diode and damage the diode, thus destroying the protective quality of
the diode.







RELAY POSITION IDENTIFICATION


Relay / Fuse block covers usually label the location and position of each fuse, relay, or
fuse element contained within.















APPLICATION OF RELAYS

Relays are remote control electrical switches that are controlled by another switch, such as a
horn switch or a computer as in a power train control module. Relays allow a small current
flow circuit to control a higher current circuit. Several designs of relays are in use today, 3-
pin, 4-pin, 5-pin, and 6-pin, single switch or dual switches.

RELAY IN A HORN SWITCH











RELAY IN A IGNITION SWITCH KEY

When the ignition key is turned all the way to the "start" position, it allows electricity to flow
to the starter solenoid (relay) which then connects the battery to the starter motor. So why do
we need this solenoid "middle man" ? Couldn't we just eliminate it and connect the ignition
wires to the + battery terminal and the other wire to the starter motor? The important point
here is that the electromagnet is using a small amount of current to control a large amount of
current to the starter motor. (Remember that the electromagnet and the switch are NOT
connected electrically). Have you noticed that all of the wires (except the ignition wires) are
purposely drawn with thick lines? The reason being that some circuits (such as the starter) in
a car require a tremendous amount of current. (If you look at an automobile's battery cables,
you will notice they are quite thick.) Connecting the ignition wires to the battery and then to
the starter motor would cause these thin wires to conduct much more current than they were
designed for. These wires would become very hot and the insulation would start to smoke.
(The same would hold true for the ignition switch). After starting the car for just a few times,
the wires and the switch would be in bad shape.
We do have a second choice. We could use thick battery cables for the ignition wires
and use a heavy duty ignition switch. This isn't very practical either. Do you think it would be
easy to squeeze cables into the steering column and to squeeze in a heavy duty ignition
switch too? Therefore, the use of a solenoid is the most practical solution.











RELAYS IN BURGAR ALARM
Another practical use of relays is for switching one circuit 'on' when another circuit has been
switched 'off' or broken. What possible application requires such an odd switching
arrangement? How about a burglar alarm?



Referring to the above diagram, let's trace the electrical flow. Since the alarm loop wire
connects points 'V2' to 'C', it can easily be seen that electricity flows from the negative
battery terminal, goes to V1 then V2, then (because the alarm loop is unbroken) it goes to C
and finally to the positive battery terminal. In this circuit, current is flowing through the
electromagnet, causing the SPDT switch to make contact with terminal B. Because of this,
the siren does NOT sound because there is NO current going to point A.
Now let's suppose that the alarm loop is broken. The wire does not necessarily have to
be cut to trigger the alarm. Perhaps one or more magnetic switches could be wired in series in
the alarm loop and when one magnet moves, it causes the switch contact to break and then
the alarm will sound. The electricity is now flowing across points C and A to the siren and
NOT the electromagnet.
Alarm Circuit 1 does suffer from one serious flaw. Can you see what it is? If the alarm
loop is reconnected, the siren shuts off. This is NOT recommended for any serious alarm
system. After all, if a door with a magnetic switch is forced open, all a burglar would have to
do is close the door. The siren then goes off ! Is there a better way to wire an alarm? Sure.





Alarm Circuit 2 looks very similar to Circuit 1, the only difference being that one side
of the alarm loop now goes to point B instead of point C. What happens when current is
applied to this circuit? The siren sounds off immediately and stays on continuously. Hmmm,
that sure seems like an annoying alarm circuit. (Did Tim Conway's father wire it? If you don't
get this joke, see Part I).
Now for the 'beauty' of this clever circuit. By using a scrap of wire, temporarily
connect point B to point C. The alarm shuts off immediately. If you break the alarm loop, the
siren sounds once again. What happens if the alarm loop is reconnected? The siren still blasts
away. Now that's a much better alarm circuit! Let's see how it works. Temporarily connecting
points B and C causes current to flow through the electromagnet, which attracts the switch to
point B. As long as the alarm loop remains unbroken the alarm remains silent. Break the
alarm loop, the alarm sounds. Unlike Circuit 1, reconnecting the alarm loop no longer causes
current to flow through the electromagnet. The only way to activate the electromagnet is by
connecting points B and C. All right!






BIBLIOGRAPHY
The various sources were used for gathering valuable information for this
report:
www.cselectric.co.in
www.wikipedia.com
www.google.com
www.autoshop101.com
www.electrical4u.com
Manuals provided at various units