ELECTRICAL BASIC

CONTACTOR

• A contactor is an electrically controlled switch

used for switching an electrical power circuit.
• They are classified power and auxilary
contactors.
• Coil supply used +24V DC and 230V AC
Motor Protection Circuit Breaker or MPCB
• Protection against electrical
faults such as short circuits,
line-to-ground faults, line-to-
line faults, phase unbalances
and phase loss. when a
motor draws electric
current above its nameplate
value (which is set as per
manual or motor name plate
current) for an extended
period of time, it will trip and
disconnect the motor from
power.
 MCCB (Moulded Case Circuit Breaker)

• MCCBs can protect

motors against overload
and short circuits.
MCCBs can also provide
under-voltages, earth
faults and phase failure
faults. Overload, short
circuit and trip delay
time can be set based
on requirement.
 Miniature Circuit Breaker [ MCB ]

• MCBs are commonly

used in low voltage
electrical networks
instead of fuses. It
automatically switches
off the electrical
circuit during the
abnormal conditions of
the network (both
overload and fault
conditions)
 DIN Rail Mounted Relays

• A relay is
an electrically operated switch It
consists of a set of input terminals
for a single or multiple control
signals, and a set of operating
contact terminals. The switch may
have any number of contacts in
multiple contact forms, such as
NO contacts, NC contacts, or
combinations of both.
 THERMISTOR PROTECTION UNIT (TPU)
• The resistance at normal
temperatures is relatively low.
temperature rise of a few
degrees results in a large
increase in resistance. The
resistance is monitored by
a thermistor protection
unit and, when the change in
resistance is detected by the
thermistor protection unit, it
operates a contact to initiate
an alarm or to trip the
protected device.
 Line Reactor
• A line reactor (also referred to as a "choke") is a variable
frequency drive (VFD) accessory that consists of a coil of
wire that forms a magnetic field as current flows through
it. This magnetic field limits the rate of rise of the current,
thus reducing harmonics and protecting the drive from
power system surges and transients. There are two
primary types of reactors used in variable frequency
drives: AC & DC. When an AC reactor is placed between
the power system and the drive, it is referred to as an AC
line reactor. When a DC reactor is inserted into the DC link
of a variable frequency drive, it is known as a DC link
reactor.

• Both AC and DC reactors limit harmonic currents.

However, AC reactors have the significant advantage of
protecting the entire VFD from power system surges and
transients since they are placed between the power
system and the incoming power terminals at the drive.
Reactors can prevent overvoltage trips, increase the
reliability and life span of the VFD, improve total power
factor, and reduce nuisance tripping.
 programmable logic controller (PLC)
• A programmable logic
controller (PLC) is an
industrial digital computer.
They can be designed for
many arrangements of
digital and analog I/O.
Programs to control
machine operation are
typically stored in battery-
backed-up or non-volatile
memory.
 HMI (DISPLAY)
• A Human-Machine Interface
(HMI) is a user interface,
that connects a person to a
machine, system, or device.
HMIs can be used to Visually
display online data,track the
production with time,
reports,trends and Monitor
machine inputs and
outputs.
 proximity switch
• A inductive proximity sensor can detect metal
targets approaching the sensor, without
physical contact with the target. A high-
frequency magnetic field is generated by coil L
in the oscillation circuit. When a target
approaches the magnetic field, an induction
current (eddy current) flows in the target due
to electromagnetic induction. As the target
approaches the sensor, the induction current
flow increases, which causes the load on the
oscillation circuit to increase. Then, oscillation
attenuates or stops. The sensor detects this
change in the oscillation status with the
amplitude detecting circuit, and outputs a
detection signal.
• M8 – 1 mm
• M12 – 1.5 mm
• M18 – 2 mm
• M30 – 5mm
 variable frequency drive (VFD)

• A variable frequency drive (VFD)

is a type of motor controller that
drives an electric motor by
varying the frequency and voltage
of its power supply. The VFD also
has the capacity to control ramp-
up and ramp-down of the motor
during start or stop, respectively.
• Even though the drive controls
the frequency and voltage of
power supplied to the motor, we
often refer to this as speed
control, since the result is an
adjustment of motor speed.
 variable frequency drive (VFD)

• Save energy and improve system efficiency

• Convert power in hybridization applications
• Match the speed of the drive to the process
requirements
• Match the torque or power of a drive to the process
requirements
Improve the working environment
Lower noise levels.
• Reduce mechanical stress on machines to extend their
lifetime
Save peak consumption to avoid peak-demand prices
and reduce the motor size required
 Danfoss FC302 Inverter factory reset
procedure
Through parameter reset
• Go to parameter 14-22 Operation
Mode and press [OK].
•
Scroll to Initialization and press [OK].
• Switch off power to the unit and wait
for the display to turn off.
• Switch on power to the unit.
• Default parameter settings are
restored during start-up.
• Start-up takes slightly longer than
normal.
• After, Drive initialized (A80) message
will appears.
• press [Reset].
Manual reset
• Switch off power to the unit and
wait for the display to turn off.
• Press and hold [Status], [Main
Menu], and [OK] buttons
simultaneously.
• After switch on the power,
approximately 5.
• Start-up takes slightly longer
than normal.
• After, Drive initialized (A80)
message will appears.
• press [Reset].
 Braking resistor

• When an decelerating load on a

motor causes the motor to turn
faster than the synchronous
speed set by a drive, the motor
acts as a generator and
transforms mechanical energy
from the motor shaft into
electrical energy. This AC power
from the motor flows backward
into the drive and causes the DC
bus voltage to increase. Unless
this regenerative energy is
dissipated, once the DC bus
voltage reaches a certain value,
the drive will trip on bus
overvoltage in order to protect
itself.
 Incremental encoder
• An Incremental encoder is electro-
mechanical, it works by transforming
the angular position of the shaft into
digital or pulse signals by means of an
optical disk. A certain number of
pulses are generated per revolution
and each pulse is an increment
corresponding to the defined
resolution. An incremental encoder
can measure the change in position
but not the absolute position.
• which allows them to monitor the
movements of high speed
mechanisms. Because of this,
incremental encoders are commonly
used in applications that require
precise measurement and control of
position and velocity.
 Magnetic rotary encoders

• Encoders used to
Monitoring the speed,
count and direction.
• In our ring frame, speed
frame and draw frame
machines were using
Magnetic rotary encoders.
• Sensor to magnetic rotor
gap recommended 04mm
– 0.6mm
• Supply voltage 8-28V DC
 Servo motor and drive
• Servo motors are part of
a closed-loop system and
are comprised of several
parts namely a control
circuit, servo motor, servo
drive and either an
encoder or resolver.
• The output shaft of this
motor can be moved to a
particular angle, position
and velocity that a
regular motor does not
have.
 Switched Mode Power Supplies (SMPS)

• A regulated power
supply converts
unregulated AC
(Alternating Current) to
a constant DC (Direct
Current). A regulated
power supply is used to
ensure that the output
remains constant even
if the input changes.
 ON delay Timers

• On delay, timers are the most

used timer in electric circuit.
The word itself you may come
to know, that “on delay =
delayed on”. It means the timer
does not give the contact
changeover until the preset
time reached.
• After reaching the preset time
the timer makes the contact
changeover. Such Timers are
called On delay timers.
• Time can be set 3sec to 30 min
 Differential pressure switch
• A differential pressure switch is a device
which utilizes a differential air pressure to
actuate an electric switch at a pre-set
actuation point. This may be the difference
between two positive or two negative
pressures, one of each, or a positive and
atmospheric or a negative and atmospheric
pressure. The electric switch may be used
to start or stop motors or fans, open or
close dampers or warning signal, sound
alarms, etc.
• Blowing reference connected to +ve port
and suction reference connected to –ve
port.
• Input supply +24V DC
 pressure transducer
• A pressure transducer or
pressure transmitter is used
to change the applied
pressure to an electrical
signal which is
measurable.output either
voltage (0-10V) or current (4-
20mA).
• We used at carding LA7/6
chute, conti-feed system, ring
frame LR9 compact suction
and pneumafil suction.
 B&R display screen calibration

• Switch off the power

•Remove the communication plug from
display.
• switch on the power and wait until the
calibration screen appears
•After done the calibration again plug the
communication cable.
Before switch on the power should check and ensure following points

• Ensure the incoming fuse and cable as

machine recommendation
• Ensure machine double earth connected
properly from earth bar and up to pit.
• Ensure the components, motors and terminals
tightness.
• Ensure the shield earth of communication and
power cables.
• Incoming 4th core should be connected to
earth at both ends, machine as well as DB
side.
• Should not connect any power capacitors at
machine and DB panels.
• After switch on the power ensure the
incoming voltage 415V AC +/- 6%.
 Pre Commissioning procedure of machines

1.Main power transformer earthing to be checked and confirmed.

50mm X 6mm Copper or GI to be connected from Body and Neutral
and to be connected to separate earth Pit – 4 Nos. Earth Pit
resistance should be less than 1 Ohms.

2. Ensure whether the Transformer is equipped with Automatic On

load Tap changer and measure secondary voltage which should be
415V AC. This voltage to be measured at load end.

3. Ensure MV panel firm connection to all Power distribution panel.

4. Ensure Power capacitor should not be powered at MV Panel stage

(at Power House) when the project is powered up. Over
compensation of Power capacitor will lead to large extent of Voltage
transients.

5. Ensure separate earth pit – 2Nos is connected by 50 X 6mm Copper

6. Ensure separate earth pit – 2Nos is connected by 50 X 6mm
Copper / GI to individual department Power Distribution panel and
its earth resistance should be less than 1 ohm.

7. Ensure firm cable connection in the individual department power

distribution board.

8. Ensure No power capacitor should be connected to Speed frame

and Ring frame Power distribution panel. If the provision is there,
the capacitor should be removed from the panel.

9. Ensure 4th core of machine incoming cable is connected firmly at

Copper strip provided in the each machine.

10. Ensure all machine earth points (Electrical panel, Machine and
Motors) is connected with earth strip (provided in the cable trench)
11. All earth joints and connection points should be firmly connected. Welding is
recommended for joining two earth plates. The earth wire from earth Plate to machine
should be connected with proper size of bolts, washer and nuts for its firm connection.

12. Ensure incoming Cable size and circuit breaker capacity or fuse is as per LMW
recommendations. Refer LMW Electrical Circuit diagram.

13. Ensure Firm connection at all machine incoming and 4th core should be connected
to earth point in the Electrical panel.

14. Ensure firm and correct connection in all power components like Inverter, Servo
drive, Induction Motors, Servo motors, Contactors and control connection at all
Terminations / Junction boxes provided in all individual machines.

15. Ensure Ring frame Main motor cable shield is properly clamped at Motor terminal
as well as in the Inverter for proper grounding.

16. Ensure Servo motor power cable shield is properly clamped in the servo drive unit
itself for proper grounding. (Only for Speed frame, Draw frame and Ring frame)
17. Measure Motor coil resistance in all machines and tabulate.

18. Ensure all inter link connections, internal control connections are as
per the Electrical circuit diagram at both end. Any mismatch in ferrule
no’s and control wire in Interlink cable between machine and panel,
Junction box and panel to be confirmed and corrected for all machines
before start up power.

19. All Electro valve coil and its electrical connection should be firmly
fixed in the machine.

20. Check and confirm Motor greasing, Belt alignment & Tension. If
Machine is stored for long duration, bearing has to be cleaned and re-
greasing has to be done before start. Belt Tension has to be checked and
confirmed as per LMW recommendation.

21. Ensure oil level in all gearboxes of gear motors. For Qty and grade –
Refer respective machine instruction manual and service
22. Before powering up any machine electrical panel, moisture content in the panel to
be removed by using heating lamp (100 – 250W) for 8 hours. During this operation,
care to be taken by electrical engineers to avoid damages to components covers, cable
channel etc due to overheat. Accordingly, heating lamp has to be placed.

23. Power up the panel and ensure incoming voltage is 415V AC +/-6%, Control
transformer tapping has to be corrected according to input voltage. Also the DC power
supply unit has to be adjusted to required DC voltage (Refer respective Machine
electrical instruction manual and service communications) by adjusting the POT in the
power supply unit.

24. Panel should be kept in Power ON condition for 8 hours – 2days to charge
capacitors in the Electronic Units. Machine should not be made ON during this time.

25. After completing the above procedure the regular commissioning procedure of the
machine should be followed. Once the bare machine commissioning is finished and if
the machine is not commissioned with material on same day then, the machine should
be kept under power ON condition (Min.4Hrs / Day) until it comes into regular
running.
Thank you