ELECTRICIAN TRADE TESTS (CLASS 1)

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.
• 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

Complied by RAS DREAD MUBEKAPI

ELECTRICIAN TRADE TESTS (CLASS 1)

(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.

Complied by RAS DREAD MUBEKAPI

ELECTRICIAN TRADE TESTS (CLASS 1)

(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
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-energising 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.

Complied by RAS DREAD MUBEKAPI

ELECTRICIAN TRADE TESTS (CLASS 1)

(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 a 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.
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

Complied by RAS DREAD MUBEKAPI

ELECTRICIAN TRADE TESTS (CLASS 1)

(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.

Complied by RAS DREAD MUBEKAPI

ELECTRICIAN TRADE TESTS (CLASS 1)

(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
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.

Complied by RAS DREAD MUBEKAPI

ELECTRICIAN TRADE TESTS (CLASS 1)

(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.

Complied by RAS DREAD MUBEKAPI

ELECTRICIAN TRADE TESTS (CLASS 1)

(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 has 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.

Complied by RAS DREAD MUBEKAPI

ELECTRICIAN TRADE TESTS (CLASS 1)

(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.

(35) A machine for molding cups and pots operates with motors. Motor Ais 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 convey or 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.

Complied by RAS DREAD MUBEKAPI

ELECTRICIAN TRADE TESTS (CLASS 1)

(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

(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.

Complied by RAS DREAD MUBEKAPI

ELECTRICIAN TRADE TESTS (CLASS 1)

(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 a 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 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)

Complied by RAS DREAD MUBEKAPI

ELECTRICIAN TRADE TESTS (CLASS 1)

(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.

Complied by RAS DREAD MUBEKAPI

ELECTRICIAN TRADE TESTS (CLASS 1)

(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

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 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.

Complied by RAS DREAD MUBEKAPI

ELECTRICIAN TRADE TESTS (CLASS 1)

(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.

(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 runnning.

Complied by RAS DREAD MUBEKAPI

ELECTRICIAN TRADE TESTS (CLASS 1)

(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.

(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.

Complied by RAS DREAD MUBEKAPI

ELECTRICIAN TRADE TESTS (CLASS 1)

(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.

(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) A 15HP 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.

Complied by RAS DREAD MUBEKAPI

ELECTRICIAN TRADE TESTS (CLASS 1)

(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

25Hp=22kw

P=√3.line voltage*line current*Cosα

Complied by RAS DREAD MUBEKAPI

ELECTRICIAN TRADE TESTS (CLASS 1)

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

Complied by RAS DREAD MUBEKAPI

ELECTRICIAN TRADE TESTS (CLASS 1)

Complied by RAS DREAD MUBEKAPI