EXPERIMENT NO 1

GRAPHICAL SIGNS AND SYMBOLS USED IN ELECTRICAL

INSTALLATION

Aim:

To study the different signs and symbols used in electrical installation

Result:

The different signs and symbols used in electrical installations are studied.
 EXPERIMENT 2

CRIMPING OF CABLES
Aim : To practice use of crimping tool and crimping of cables.

Equipments required: Crimping tool, crimping sockets, cables

Theory:
Crimping is joining 2 pieces of metal or other ductile material (usually a wire and a
metal plate) by deforming one or both of them to hold the other. The bend or deformity is
called the crimp. A crimp connection is a type of solder less electrical connection. Metals are
joined together via a special connector. Stripped wire (often stranded) is inserted through the
correctly sized opening of the connector, and a crimper is used to tightly squeeze the opening
against the wire.
An electrical connector is a device for joining electrical circuits together using a
mechanical assembly. The connection may be temporary or serve as a permanent electrical
joint between two wires. There are hundreds of types of electrical connectors. Connectors
may join two lengths of wire together or connect a wire to an electrical terminal.
Procedure:
First, the correct size wire must be chosen for the terminal size, or vice versa. Next,
strip the wire. The amount of exposed wire should be equal to the length of the metal barrel
on the connector, usually around ¼” or so. If the stripped wire fits up into the metal portion
of the barrel with little or no free space, the connector is the right size. But if the wire does
not fit in the barrel, or is excessively loose, the wrong size of either wire or connector was
chosen.
The wire should then be inserted until the insulation on the wire touches the end of the
barrel. The wire and terminal are then inserted into the crimper. The correct size is chosen by
using the gauge markings on the side of crimping tool.
The terminal should be sitting horizontal with the barrel side up. The tool is then held
perpendicular to the terminal and placed over the barrel, nearest to the ring (or other
connection type). To finish the crimp, the tool is squeezed with a considerable force. In
general, it is almost impossible to ‘over crimp’ a connection. After the crimp is completed,
the wire and connector should still hold together after trying to pull them apart with great
force. If the connection can be pulled apart, the crimp was not done correctly.

Different types of crimping sockets

 Crimping socket attached to cable

Crimping tool

Result: The method of crimping cables is practiced.

 EXPERIMENT NO 3

GLANDING OF ARMOURED CABLES

Aim: To practice the method of glanding of armoured cables.

Equipments Required:

Electrician’s Knife
Three core armoured cable
Pliers
Cable glands

Theory:
A cable gland is a device designed to attach and secure the end of cable to the
equipment. They are used as a sealing and termination device. ie., the cable is firmly fixed to
the equipment and is not disconnected from the equipment during rough handling. It provides
provision for making electrical connection to the armour or braid and lead or aluminium
sheath of the cable if any. Cable glands may be used for sealing cables passing through
bulkheads or gland plates.
Cable glands may be used on all types of electrical power, control, instrumentation,
data and telecommunications cables. These are the four main materials from which cable
glands are made.
• Plastic
• Brass
• Aluminium
• Stainless steel

Procedure:
1. Prepare the cable by removing the cable outer sheath and the armour to suit the
geometry of the equipment. Remove a further 18 mm of outer sheath to expose the
armour. If applicable remove any tapes or wrappings to expose the cable inner sheath.
Separate the cable gland entry component from sub assembly B. Ensuring that the
outer seal is relaxed, pass assembly B over the cable outer sheath and armour
followed by the anyway clamp ring.
2. Secure the entry component to the equipment as indicated.
3. Place the detachable armour cone in to recess of the entry component. Pass cable
through entry component, evenly spacing the armour around the cone.
4. Continue to push the cable forward to maintain the armour in contact with the cone
and tighten the body of sub assembly B into entry component.
5. Ensure the two components make metal to metal contact.
6. Tighten the outer seal nut until the outer seal nut makes metal to metal contact with
the gland body or the outer seal nut has clearly engaged the cable and cannot be
further tightened without the use of excessive force by the installer

Result:
The cable glanding procedure is practiced.
 EXPERIMENT NO 4

STUDY OF DOL STARTER

Aim:

To dismantle the given DOL starter to find out the defects if any and rectify them.

Equipments Required:

1) Long Nose Plier

2) Screw Driver
3) Multimeter
4) Soldering Iron
5) Tweezer
6) Soldering Flux

Theory;

This type of starter is used to start the 3 phase squirrel cage induction motor below
5HP rating. It has two push buttons. The green push button is the start button. It is a normally
open push button. The red push button is the stop push button. It is a normally closed push
button. When the start button is pressed, the no volt coil is energised. It pulls the plunger and
closes the contacts. Now the full voltage is applied to the motor through the 3 main contacts.
The fourth contact called maintaining contact helps to maintain the supply even after the start
push button is released.

In case of overload, the overload relay disconnects the circuit of no volt coil. This
releases the plunger to off position and the motor will stop.

Procedure:

1. Note the instrument details

2. Dismantle the starter.
3. Check all the terminals connections
4. Check the continuity of the coil using multimeter.
5. Take necessary remedies.
6. Re-assemble the starter and ensure it is working properly.
Result:

The given DOL starter is studied and repaired the faults.

 EXPERIMENT NO 5

STUDY OF STAR DELTA STARTER

Aim:

To dismantle the given star delta starter and find out the faults if any take necessary
remedies to correct them.

Equipments Required:

1) Long Nose Plier

2) Screw Driver
3) Multimeter
4) Soldering Iron
5) Tweezer
6) Soldering Flux

Theory:

This type of starters are used for motors above 5 HP rating. At starting, the 3 phase
stator windings are connected in star connection. The voltage across each phase will be 1/√3
of the line voltage. So the starting current will be reduced. When the motor starts rotating, the
starting current is reduced due to slip. Now the stator windings are put to delta connection
either manually or automatically. When the windings are delta connected, full line voltage
appears across each phase.

Procedure:

1. Note the instrument details

2. Dismantle the starter.
3. Check all the terminals connections
4. Check the continuity of the coil using multimeter.
5. Take necessary remedies.
6. Re-assemble the starter and ensure it is working properly.
Result:

The given star delta starter is studied and repaired the faults.
 EXPERIMENT NO 6

CONTROL CIRCUIT USING DOL STARTER

Aim

To design a control circuit using DOL starter.

Materials Required

1) MCCB three pole with neutral 32 A – 1 no

2) Digital Voltmeter (0-600) V panel type- 1 No
3) Digital Ammeter- (0-30)A Panel type- 1 No
4) DOL starter- 1 No
5) Wires

Theory:

A three phase induction motor draws morestarting current during starting. To prevent
damage to the windings due to the high current flow, we use different types of starters. The
simplest form is DOL (Direct On Line ) starter. The DOL starter is used for motors below
5HP rating. The DOL starter consists of an MCCB, Electromagnetic Contactor and an Over
Load Relay for protection.

Procedure:

• Give connection as per wiring diagram

• Switch on the MCCB
• Press the start button
• The motor is now turned on
• To stop the motor the Stop button is pressed.
Result:

A control circuit to run a three phase induction motor using DOL starter is designed.
 EXPERIMENT NO 7

CONTROL CIRCUIT USING STAR DELTA STARTER

Aim:

To design a control circuit using star delta starter.

Materials Required

6) MCCB three pole with neutral 32 A – 1 no

7) Digital Voltmeter (0-600) V panel type- 1 No
8) Digital Ammeter- (0-30)A Panel type- 1 No
9) Star Delta starter- 1 No
10) Wires

Theory:

A three phase induction motor draws more starting current during starting. To prevent
damage to the windings due to the high current flow, we use different types of starters. The
star delta starter is used for motors above 5HP rating. In star delta starter, the motor is first
started in star connection. The starting voltage is reduced to V/√3. After a few seconds the
motor is put to delta connection. Now full voltage will appear across the motor. The motor
will then continue to run in delta connection under normal operation.

Procedure:

• Give connection as per wiring diagram

• Switch on the MCCB
• Press the start button.
• The main contactor and star contactor turns on.
• After a few seconds the star contactor goes off and delta contactor is turned on.
• The motor then continues to run in delta connection.
• To stop the motor the Stop button is pressed.
Result:

A control circuit to run a three phase induction motor using star delta starter is
designed.
 EXPERIMENT NO 8

ASSEMBLING OF DOL STARTER

Aim:

To assemble a DOL starter using push buttons, contactor and OLR unit and run a three phase
induction motor.

Materials Required:

1. Indicating Lamps-Red, Yellow, Blue – One each

2. MCB 3A single pole type- 3 Nos

3. MCCB 32A three pole with neutral - 1 No.

4. Voltmeter (0-600)V MI panel type- 1 No.

5. Ammeter (0-30)A MI panel type- 1 No.

6. Voltage selector- 1 No.

7. Start push button- 1 No.

8. Stop push button- 1 No.

9. Magnetic contactor 415 V (MNX12) - 1No.

10. Thermal Over Load Relay 6-10A (MN2)- 1 No.

11. Wires

Theory:

A three phase induction Motor draws more starting current during starting. To prevent
damage to the windings due to the high starting current flow, we use different types of
starters. The simplest form of motor starter for the induction motor is the Direct On Line
starter. The DOL starter is used for motors below 5 HP rating. The DOL starter consist of a
MCCB, Electromagnetic Contactor and an Overload Relay for protection.

• MCCB ( Moulded case Circuit Breaker): The supply is first connected to an MCCB.
The MCCB gives short circuit protection. In case of fault, the MCCB will trip off the
supply.
• Electromagnetic contactor: The electromagnetic contactor is controlled by separate
start and stop push buttons. The electromagnetic contactor has three main contacts
L1, L2 and L3 and a maintaining contact represented as NO. The main contacts are
connected to the three phases of the supply. The maintaining contact is connected
 across the start button, so that the supply is maintained after we release the start
button. When start button is pressed, the supply reaches the relay coil of main
contactor. The three main contacts and maintaining contact is closed by the relay
action . The stop button is used to switch off the motor. The supply to the relay coil
is cut off by the thermal overload relay under fault conditions. So all the contacts
will go off.
• Thermal Over Load Relay: Under overload conditions, a motor draws excessive
current that causes overheating. The motor winding insulation deteriorates due to
overheating. To protect a motor from overheating, Thermal Overload relays are used
to limit the amount of current drawn. The overload relay consists of a current-
sensing unit connected in the line to the motor. A trip off mechanism will be
actuated by the sensing unit to break the circuit in case of overload.

Wiring the DOL Starter

1) Thermal OverLoad Relay
• T1, T2, T3 of Thermal Overload Relay is connected to MCCB.
• NC Contact (-|/|-): (95-96) is a normally closed NC contact. It opens
when the thermal overloads relay is activated due to over load . Then
the supply to relay coil of main contactor will be cut off.
• NC Contact point 95 of Thermal Overload Relay is connected to point
A2 of Relay coil of the Main Contactor and 96 is connected to the
other end of Stop Button.

2) Main Contact:
• L1 of Contactor Connect (NO) to R Phase through MCCB and OLR
• L2 of Contactor Connect (NO) to Y Phase through MCCB and OLR
• L3 of Contactor Connect (NO) to B Phase through MCCB and OLR.

• NO Contact (-||-):
(13-14 or 53-54) is a normally Open NO contact. It closes when the relay energizes.
Contactor Point 53 is connecting to Start Button Point (94) and Contactor Point 54 is
connected to Common point 93 of Start and Stop Button.

• Relay coil contact A1 and A2: A1 is connected to Y phase and A2 is connected to

point 95 of OLR.

3) Voltage selector: A voltage selector and voltmeter is connected to three phases as

shown in figure. The voltage across two phases ARE indicated on the voltmeter.

4) Indicating lamps with MCB: An indicating lamp in series with a MCB is

connected to each phase at the beginning of supply. It indicates the presence of
supply in each phase.
5) Ammeter: It is connected in series with one phase. It indicates the current in one
phase.
6) The outputs from main contactor is connected to terminals L1, L2 and L3 of
motor
Procedure:

1) Give Connections as per given wiring diagram.

2) Switch on the MCCB.
3) Check if all the indicating lamps are on.
4) Press the start button.
5) The motor is now turned on
6) To stop the motor Stop button is pressed.

Result:

A DOL starter is assembled using push buttons, contactor and OLR unit and a three phase
induction motor is operated using the starter.
 EXPERIMENT NO 9

ASSEMBLING OF STAR DELTA STARTER

Aim :

To assemble a star delta starter using push buttons, contactor and OLR unit and run a
three phase induction motor.

Materials Required:

1. Indicating Lamps-Red, Yellow, Blue – One each

2. MCB 3A single pole type- 3 Nos

3. MCCB 32A three pole with neutral - 1 No.

4. Voltmeter (0-600)V MI panel type- 1 No.

5. Ammeter (0-30)A MI panel type- 1 No.

6. Voltage selector- 1 No.

7. Start push button- 1 No.

8. Stop push button- 1 No.

9. Magnetic contactor 415 V (MNX12) - 3 Nos.

10. Thermal Over Load Relay 6-10A (MN2)- 1 No.

11. Star Delta Timer 240-415V- 1 No.

12. Wires

Theory:

A three phase induction Motor draws more starting current during starting. To prevent
damage to the windings due to the high starting current flow, we use different types of
starters. The star delta starter is used for motors above 5 HP rating. In star delta starter, the
motor is first started in star connection. The starting voltage is reduced to V/√3. After a short
time period set by the timer, the motor is put to delta connection. Now full voltage will
appear across the motor. The motor will then continue to run in Delta connection under
normal operation.

The star delta starter consist of a MCCB, an Electromagnetic Contactor for main contact, an
Electromagnetic contactor for star connection, an Electromagnetic Contactor for delta
connection, an Overload Relay for protection and an electronic timer for setting time period
to change over from star to delta connection.
 MCCB ( Moulded case Circuit Breaker): The supply is first connected to an MCCB. The
MCCB gives short circuit protection. In case of fault, the MCCB will trip off the supply.

Electromagnetic contactor: The electromagnetic contactor is controlled by separate start and

stop push buttons. The electromagnetic contactor has three main contacts L1, L2 and L3 and
a maintaining contact represented as NO. The main contacts are connected to the three
phases of the supply. The maintaining contact is connected across the start button, so that the
supply is maintained after we release the start button. When start button is pressed, the supply
reaches the relay coil of main contactor. The three main contacts and maintaining contact is
closed by the relay action . The stop button is used to switch off the motor. The supply to the
relay coil is cut off by the thermal overload relay under fault conditions. So all the contacts
will go off.

Thermal Over Load Relay: Under overload conditions, a motor draws excessive current that
causes overheating. The motor winding insulation deteriorates due to overheating. To protect
a motor from overheating, Thermal Overload relays are used to limit the amount of current
drawn. The overload relay consists of a current-sensing unit connected in the line to the
motor. A trip off mechanism will be actuated by the sensing unit to break the circuit in case
of overload.

Wiring the Star Delta Starter

(1) Thermal OverLoad Relay

 T1,T2,T3 of Thermal Overload Relay is connected to MCCB.
 NC Contact (-|/|-):
(95-96) is a normally closed NC contact. It opens when the thermal overloads relay is
activated due to over load . Then the supply to relay coil of main contactor will be cut off.
 NC Contact point 95 of Thermal Overload Relay is connected to point A2 of Relay coil of
the Main Contactor and 96 is connected to the other end of Stop Button.

(2) Main Contact:

 L1 of Contactor Connect (NO) to R Phase through MCCB and OLR
 L2 of Contactor Connect (NO) to Y Phase through MCCB and OLR
 L3 of Contactor Connect (NO) to B Phase through MCCB and OLR.
 NO Contact (-||-):
(13-14 or 53-54) is a normally Open NO contact. It closes when the relay energizes.
Contactor Point 53 is connecting to Start Button Point (94) and Contactor Point 54 is
connected to Common point 93 of Start and Stop Button.
 Relay coil contact A1 and A2: A1 is connected to Y phase and A2 is connected to point 95
of OLR.

(3) Voltage selector : A voltage selector and voltmeter is connected to three phases as shown
in figure. The voltage across two phases is indicated on the voltmeter.
(4) Indicating lamps with MCB: An indicating lamp in series with a MCB is connected to each
phase at the beginning of supply. It indicates the presence of supply in each phase.

(5) Ammeter: It is connected in series with one phase. It indicates the current in one phase.

(6) The outputs from main contactor is connected to terminals A1, B1 and C1 of motor.

(7) The three phases are given to the L1, L2 and L3 terminals of the delta contactor. The
terminals T1, T2 and T3 of delta contactor is connected to C2, A2 and B2 of motor
respectively.

(8) The terminals T1, T2 and T3 of delta contactor is connected to T1, T2 and T3 of star
contactor respectively. The terminals L1, L2 and L3 of star contactor is shorted.

(9) The B phase and neutral is connected to A2 and A1 terminals of Timer. The pin 18 and 25
are connected to the phase. The pin 15(star) is connected to A1 of star contactor and pin
25(delta) is connected to A1 of delta contactor.

Procedure:
• Give Connections as per given wiring diagram.
• Switch on the MCCB.
• Check if all the indicating lamps are on.
• Press the start button.
• The main contactor and star contactor turns on.
• After the short time set in the timer, the star contactor goes off and delta contactor is
turned on.
• The motor then continue to run in delta connection.
• To stop the motor Stop button is pressed.
Result:
A star delta starter is assembled using push buttons, contactor and OLR unit and a three
phase induction motor is operated using the starter.
 EXPERIMENT NO 10
PANEL BOARD TO CONTROL A 5 HP MOTOR

Aim:

To design a panel board with all essential parts for controlling a 5HP motor.

Materials Required:

1) 3 phase energy meter, 60A – 1 No.

2) Fuse, 32 A, Kit kat type- 3 Nos
3) 3 phase, 32 A 3 pole with neutral cubicle main switch – 1 No.
4) 3 phase 40A ELCB – 1 No
5) Indicating Lamps-Red, Yellow, Blue- 1 each
6) Voltage selector – 1 No
7) Voltmeter (0-500)V MI panel type – 1 No
8) Ammeter (0-30)A MI panel type – 1 No
9) 3 pole 40 A isolator – 1 No
10) DOL starter- 1No
11) 2 KVAR capacitor- 1 No.
12) MS panel board- 90 cm x 75 cm x 8 cm – 1 No
13) Wires for connection

Theory:

To control a 5 HP motor, necessary protection must be given. To set up a 5 HP motor

in a factory, the connections are made as shown in figure. The 3phase supply from the service
provider is given to the 3 phase energy meter. The output from energy meter is given to 32 A
fuses. From the fuse the connection is given to the cubicle main switch. From the main
switch, the connections are given to ELCB. From ELCB , the connection is given to 3 pole
isolator. From the isolator, the connection is given to DOL starter. From the DOL starter, the
connection is given to 3 phase induction motor. A 2 KVAR capacitor is connected in parallel
to improve power factor.

Function of each part:

1) Cubicle Main Switch- It is used as a main switch. It has protective fuses for
protection.
2) ELCB (Earth Leakage Circuit breaker) – It protects the circuit and equipment from
earth leakage fault. It trips off the supply in the event of earth fault.
3) Isolator- It is used to disconnect ornconnect the circuit. It acts as a switch.
4) DOL starter- It is used to limit the starting current to the motor.
5) Capacitor- It is used to improve power factor of the motor.
Procedure

1) Wire the circuit as per diagram.

2) Ensure that all the protective devices MCCB, ELCB, isolator are switched off before
powering the circuit.
3) After supply is given, the MCCB, ELCB and isolator is switched on.
4) After this, the DOL starter is pushed on to start the motor.

Result:

A panel board to control a 5 HP motor is designed.

 EXPERIMENT NO 11

PANEL BOARD TO CONTROL THREE 5 HP MOTORS

Aim:

Design and set up a panel board to control three 5HP motors

Materials Required:

1) Cubicle Main Switch 100A, 440V – 1 No

2) Busbar conductor(copper or aluminium) – 1 inch x 3mm x 5 metre length
3) Copper wire 10 SWG size- 5 metre length
4) 3 pole isolator , 40A , 440V – 3 Nos
5) 3 phase DOL starter, 440V, 15A – 3 Nos
6) RYB indicators – 3 Nos
7) MS sheet Panel Board – 125cm x 100cm x 45 cm
Theory:

This type of panel board is used to set up a control panel to control more than one
motor. The supply is first given to a 3 phase cubicle main switch which is placed inside the
incomer chamber. From the main switch, bus bars are used to take connection. Each phase is
given to one bus bar. From the 3 bus bars, the connections are given to three pole isolators
using 10 SWG copper wires. From 3 pole isolators, the connection is given to the DOL
starter. From the DOL starter, the connection is given to the 3 phase induction motor.

Procedure:

1) Make the connections as per wiring diagram.

2) Ensure that all the isolators are in off position.
3) Switch on the supply.
4) Switch on the isolator and then the starter to operate the motor.

Result:

A panel board is designed to control three 5HP motor.