ELECTRICAL HAND BOOK 1

TROUBLE SHOOTING

CABLE-SIZE & CB CURRENT RATING

For lighting points use 1.5mm2 PVC Cable.

• Up to 15A - 2.5 mm2 • Up to 175A - 95 mm2

• Up to 20A - 4 mm2 • Up to 200A - 120 mm2

• Up to 30A - 6 mm2 • Up to 225A - 120 mm2

• Up to 40A - 10 mm2 • Up to 250A - 150 mm2

• Up to 50A - 16 mm2 • Up to 300A - 185 mm2

• Up to 60A - 25 mm2 • Up to 350A - 185 mm2

• Up to 75A - 35 mm2 • Up to 400A - 240 mm2

• Up to 100A - 50 mm2 • Up to 500A - 300 mm2

• Up to 120A - 70 mm2 • Up to 630A - 400 mm2

• Up to 150A - 95 mm2 • Up to 750A - 500 mm2

• Up to 1000A - 630 mm2

• 300 A and above should be EF/OC that means earth fault and overcurrent type relay to use.

• 200 A and under should be ZCT and ELR Zero sequence Current Transformer and Earth Leakage Relay
to use.

• Main DB Cable Type are as follows:

• For inside the building PVC/PVC or XLPE/PVC type.

• For Under Ground PVC/SWA/PVC type.

• Sub-Main DB cable type should be PVC only.

• From 3.3KV up to 22KV should use PVC/SWA/PVC or XLPE/DSTA/PVC type.

• ECC and N choice.

• 1.5 mm2 to 16 mm2 Phase cables should use N-full size and E-half size

• 25 mm2 and above should use N-half size and E-half size.

• Maximum Earth Cable size is 70 mm2

• CB rating and maximum interrupt current capacity are as follows

CB Rating for Normal Maximum Interrupt Current Cap.

800A - 1250A 50KA

175A - 630A 35KA

0 - 150A 25KA

0 - 100A 10KA

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 ELECTRICAL HAND BOOK 2
TROUBLE SHOOTING
0 - 100A 22KA

2500A 31MVA for 3 Sec

400A 36KA

150A 25KA

60A, 63A MCB 10KA

20A MCB 5KA

MAXIMUM DEMAND CALCULATION
ACCORDING TO SAA WIRING RULES AS 3000
AS 3000-1991
AUSTRALIA STANDARD
SAA WIRING RULES
Table 2.3
MAXIMUM DEMAND-SINGLE AND MULTIPLE
DOMESTIC INSTALLATION
1 2 3 4 5
Block of living unit
Load Group Single domestic 2 to 5 living 6 to 20 21 or more
installation or unit per living units living units
individual living unit phase per phase per phase
per phase
A Lighting
(i) Except as in (ii) and load 3A for 1 to 20 points + 6A 5A+0.25A 0.5A per
group H below 2A for each additional 20 per living living unit
points or part thereof unit
(ii) Outdoor lighting 75% connected load No assessment for the purpose of maximum
exceeding a total of 1000W demand.
B (i) GPOs and socket-outlets 10A for 1 to 20 points + 10A+5A per 15A+3.75A 50A+1.9A
not exceeding 10A. 5A for each additional 20 living unit per living per living
Permanently connected points or part thereof unit unit
equipment not exceeding
10A and not included in
other load groups.
(ii) Where the installation 10A 10A 10A 10A
includes one or more
15A socket-outlets other than
socket outlets provided to
supply equipment set out in
groups C,D,E,F,G and L
(iii) Where the installation 15A 15A 15A 15A
includes one more 20A
socket-outlets provided to
supply equipment set out in
groups C,D,E,F,G and L
C Ranges, cooking, appliances, 50% connected load 15A 2.8A per 2.8A per
laundry equipment or socket- living unit living unit
outlets rated at more than
10A for the connection
thereof
D Fixed spaced heating or air 75% connected load 75% 75% 75%
conditioning equipment, connected connected connected
saunas or socket-outlets rated load load load
at more than 10A for the
connection thereof
E Instantaneous water heaters 33.3% connected load 6A per 6A per 100A+0.8A
living unit living unit per living
unit
F Storage water heaters Where the full load current is less than the figure obtained under the
(i) controlled load other appropriate load groups, no assessment for the purpose of
maximum demand. see footnotes
(ii) other types Full-load current 6A per 6A per 100A+0.8A
living unit living unit per living
unit
G Spa and swimming pool 75% of the largest spa, plus 75% of the largest swimming pool, plus
heaters 25% of remainder.

LOADING NOT ASSOCIATED WITH INDIVIDUAL UNITS-CONNECTED TO EACH PHASE (PUBLIC

LIGHTING, COMMUNITY LAUNDRY LOADINGS, LIFTS, MOTORS, ETC.)
H Communal lighting Not applicable Full connected Full connected Full connected
load load load
I GPOs and socket-outlets not Not applicable 2A per point 2A per point 1A per point
included in-groups J and M
below.

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Permanently connected
equipment not exceeding
10A
J Appliances rated at more Not applicable 50%connected 50%connected 50%connected
than 10A and socket-outlets load load load
for the connection thereof-
(i) Clothes dryers, water
heaters, self heating washing
machines, wash boilers
(ii) Fixed spaces heating , air Not applicable 75%connected 75%connected 75%connected
conditioning equipment, load load load
saunas
(iii) Spa and swimming pool Not applicable 75% of the largest spa plus 75% of the largest
heaters swimming pool, plus 25% of the remainder
K Lifts In accordance No assessment for purpose of calculation of maximum
with Clause demand. In accordance with Clause 2.6.3, Table 2.4,
2.6.3 Table 2.4 determination of size of submains.
L Motors In accordance In accordance with Clause 2.6.3, Table 2.4, column 2
with Clause
2.6.3 Table 2.4
column 2
M Appliances, including Connected Connected load 10A or less. No assessment for
socket-outlets other than Load 5A or purpose of maximum demand.
those set out in group A to L less: No
above. e.g. pottery kin, assessment for
welding machines, radio purpose of
transmitters, X-ray maximum
equipment and the like demand.
Over 5A by Connected load over 10A. by assessment of the
local authority inspecting Authority
permission
Footnotes to table 2.3
a.For multiphase connections, divide the number of living units by the number of supply phases, e.g. 16units
on a three phase supply, 16/3 = 6 units on the heaviest loaded phase (Column 4)
b.Where only a portion of the number of units in a multiple installation is equipped with permanently
connected or fixed appliances, such as electric cooking ranges or space heating equipment, the number of
appliances in each category is divided over the number of phases, and the maximum demand determined as
shown in Example 3 of Appendix G.
c.Lighting track systems shall be regarded as 2 points per meter of track.
d.This load group is not applicable to socket-outlets installed in Communal area but not connected for the
individual living units. Su /ch socket outlets should be included in load group B.
e.For purpose of determining maximum demand, multiple combination socket-outlets shall be regarded as the
same number of points as the number of integral socket-outlets in combination.
f.Where an installation contains 15A or 20A socket outlets covered by load group B(ii) or B(iii), the base
loading of load group B is increased by 10A or 15A respectively; if both 15A and 20A socket-outlets are
installed. The increased is 15A.
g.Where and installation includes an air-conditioning system for use in hot weather and a heating system for
use in cool weather, only that system which has the greater load shall be taken into account.
h.Flood lighting, swimming pool lighting and tennis court lighting and like
i.Instananeous water heaters including 'quick recovery' heaters having element ratings greater than 100W/L
j.Storage type water heaters, including 'quick recovery' heaters not referred to in footnotes.
k.Controlled loading is taken to include only loading to which supply is controlled by the supply Authority so
that it is available only for limited period of time. Where the full load current of the controlled load exceeds
the maximum demand calculated using all appropriate items of this Table, the full load current of the
controlled load together with group A(ii) and group H shall be taken as the maximum demand for the
installation.
l.In the calculation of the connected load, the following rating shall be assigned to lighting.
(i) Incandescent lamps 60W or the actual wattage of the lamp to be installed, whichever is
greater,
except that if the design of the lumanrie associated with the lampholder
permits only lamps of less than 60W to be inserted in any lampholder, the
connected load of that lampholder shall be the wattage of the highest rated
lamp which may be accommodated. For multi-lamp luminaries, the load
for each lampholder shall be assessed on the above basis.
(ii) Fluorescent and Full connected load, i.e. the actual current consumed by the lighting
other discharge arrangement having regard to auxiliary equipment such as ballast and
lamp capacitors.

(iii) Lighting Tracks 0.5A/m per phase of track or the actual connected load, whichever is
greater.

m. A socket outlet installed more than 2.3 m above a floor for the connection an appliance rated at not
more than 100W or a lumanrie may be included as a lighting point in load group A(i). An appliance
having not exceeding 100W, which is permanently connected or connected by means of a socket
outlet installed more than 2.3m above a floor, may be considered as a lighting point.
n. Each item of permanently connected equipment not exceeding 10A may be included in load
group B(i) as an additional point.

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1 2 3
Load group Residential Institutions, Factories, shops, stores,
hotels, boarding houses, offices, business
hospital, accommodation premises
houses, motels
A. Lighting other than in load group F 75% connected load Full connected load
B.
(i) GPOs and socket outlets not exceeding 1000W for first socket outlet 1000W for first socket
10A other than those in B(ii) plus 400W for each additional outlet plus 750W for each
outlet. additional outlet
(ii) GPOs and socket outlets not exceeding 1000W for first socket outlet 1000W for first socket
10A in building or potions of buildings plus 100W for each additional outlet plus 100W for each
provided with permanently installed outlet. additional outlet.
heating or cooling equipment or both.
(iii) Socket outlets exceeding 10A Full current rating of highest Full current rating of
rated socket outlets plus 50% of highest rated socket
full current rating of remainder outlets plus 75% of full
load of remainder
C. Appliances for cooking, heating and Full current rating of highest Full current rating of
cooling, including instantaneous water rated appliance plus 50% of highest rated appliance
heaters, but not appliances included in full current rating of remainder plus 75% of full current
group D & J. rating of remainder
D. Motor other than in E and F below Full load of highest rated motor Full load of highest rated
plus 50% of full load of motor plus 75% of
remainder second highest rated
motor plus 50% of full
load of remainder
E. Lifts (i) Largest lift motor - 125% full load
(ii) Next largest lift motor - 75% full load
(iii) Remaining motors - 50% full load
For the purpose of this load group, the full load current of a
lift motor shall mean the current taken from the supply
when lifting maximum rated load at maximum rated speed.
F. Fuel dispensing units (i) Motors : First motor - full load
Second motor - 50% full load
Additional motor - 25% of full load
(ii) Lighting - full connected load
G. Swimming pools, spas, saunas, thermal (i) Continuous elements - full load in all cases
storage heaters including water heaters, (ii) Controlled elements (including controlled element
space heaters, and similar arrangements which may be connected to the supply at other than
controlled times by means of a change over switch or load
controlled systems): 66% of full load where the demand of
the rest of the installation as calculated is not less than that
of the controlled element.
Full load in all other cases
H. Welding machines In accordance with clause 2.6.4, takings into account power
factor correction.
J. X-ray equipment 50% of the full load of the largest X-ray unit, additional
units being ignored.
K. Other equipment not covered by load By assessment of the inspecting Authority
group above
a. In the calculation of connected load, the following ratings shall be assigned to lighting:
(i) Incandescent lamp - 60W or the actual wattage of the lamp to be installed, whichever is the
greater, except that if the design of the luminaries associated with the lampholder permits only lamps
of less than 60W to be inserted in any lamp holder, the connected load of lamp holder shall be the
wattage of the highest rated lamp which may be accommodated. For multi - lamp luminaries, the
load for each lampholder shall be assessed on the above basis.
(ii) Fluorescent lamp - Full connected load, i.e. the actual current consumed by the lighting
arrangement having regard to auxiliary equipment such as ballast and capacitors.
b. Load group B(ii) applies to building or portion of building incorporating permanently installed
heating and/or cooling equipment specifically provided to render unnessary to the use of general-
purpose outlets for portable electric space heating or cooling appliances. Whether heating or cooling
or both is deemed necessary to avoid the use of portable heating or cooling equipment will depend on
the location and climate involved.
c. Controlled loading is taken to include only loading to which supply is available for a limited
Period of time.
d. A socket outlet installed more than 2.3m above a floor for the connection of an appliance rated at
not more than 100W or a luminary may be included as a lighting point in load group A. An
appliance having a rating not exceeding 100W, which is permanently connected, connected by
means of a socket outlet installed more than 2.3 m above a floor may be considered as a lighting
point.
e. See clause 2.5 9(ii) , Clause 2.8.2 and clause 2.9.3 for where the maximum demand for
consumers main and submains, and final subcircuits respectively may be determined by limitation.

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 ELECTRICAL HAND BOOK 5
TROUBLE SHOOTING

TRANSFORMER TROUBLE SHOOTING

s Parts Trouble Possible
no.
1 Insulation oil • Overheat • Lower than oil level.
• Block oily dirt in cooling lines.
• Overload.
• Weak in di-electric • Water moisture, vapor, dirt include in oil
strength flowing, because breathing equipment can't
clean them.
• Bad in Gaskets as wears and tears.
• Acid and oily dirt • Overheating.
come out • Oil viscosity not corrects.
2 Breather • Not absorb water • Something damages or not corrects in
moisture chemical.
3 Windings • Overheating • Overload
• Lower in oil level.
• So many oily dirt in bottom of oil tank.
• Oily dirt blocks in cooling pipelines.
• Noisy • Losing in clamps or Bolts & nuts
• Weak in insulation • Water includes in oil or acid includes in oil.
resistance • Touch in air.
• Not enclosed with air.
4 Core • Overheating • Core insulation damage.
• Noisy • Loosing in bolts and nuts.
5 Insulation • Hard & easy to • Overheating
crack • Very long in life or life in finish.
6 Enclosure • Rust • Acid in oil
(Air part)
7 Thermometer • Not correct • Not correct in Connection.
indication • Some problem in Bulb or Tube.
Remark: There are 75-degree centigrades to 80-degree centigrade in oil temperature. It must be filled in oil
level that is pre-mark. It must not be leakage in oil tube, drain cock, gasket. If there are water in oil, the color
will be mud color. But should not assume as always.
Crack test: The method which is the best way to know whether oil mix with water or not.
method: (1) close one end of capillary tube, size in 1-inch diameter.
(2) heat until red-brown color.
(3) poured into sample oil which you want to know, and listen by the other end.
no water inside-sh!!
water inside-explode!!
Silica Gel: It is a type of chemical which absorbs moisture or vapor. It will slowly change the violent color to
pill pink color as ratio which absorbed moisture or vapor. It must be change new silica gel where the old is
totally pink color.
heat treatment: When 300 degree F to 400 degree F heating to old silica gel, the color get it back original
violent that is to get it out moisture or vapor.
It should be inspected in every 6-month or 1-year regularly.
TRANSFORMER MAINTAINANCE
1. External seeing inspection.
2. Using instruments inspection

1.External seeing inspection

(1) Insulation oil leakage or little than marking.: Put red color float into oil indicator glass & see. If it
is lower than marking, it is known as not enough oil.
(2) Blue color crystal change in color or not: Breather crystal which is blue color change to pink color
means saturated in moisture or vapor, must be change or put under sun or heat supply.
(3) Porcelain & ceramic isolator crack or not

2. Using Instrument inspection

(1) Winding insulation testing. : LT winding testing - short circuit to HT winding line 3 terminals.
• also short circuit to LT winding lines 3 terminals.
• take off Earth wire
• Megger testing: Line to LT short terminal &
• Earth to Transformer body.
: HT winding testing - similarly as LT winding testing.
: Test Result: not lower than 1000 ohms/v is good

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TROUBLE SHOOTING
: for 230V is good in 230K-ohms or 0.23M-ohms
: for 400V is good in 0.4M-ohms
: for 11KV is good in 11M-ohms
Insulation oil condition testing.: Get the sample oil which can get transformer bottom oil drain hole
• Testing by Insulation oil tester
• Wash to Sphere in instrument by oil.
• After no more bubble in oil, line switch on.
• Put until 11KV & slowly increase.
• Wait a moment when every 5KV increase.
• Nothing happen until 40KV - it is good.
• If oil is not pure spark between two sphere & automatic trip.
• It must be stand 1min in 40KV.
• When testing 5 times- 4 times were in good, oil is good.
• Some type of oil can stand 45KV to 50KV.
(Reference by U Pe Thein )
Earth testing or Ground testing.

Transformer Troubleshooting
Sr.no. Symptom Trouble Cause Remedy
1 Temperature of oil 1a. Overload 1a. Poor powerfactor 1a. Decrease load and
cooled transformer and overload powerfactor
rise until serious correction
level.
1b. Not enough oil in 1b. Leak in oil tank 1b. Repair it, or oil
oil tank or not enough fill until
filling transformer core
is under oil level
1c. Oil viscosity 1c. Cannot transfer 1c. If it was
grade so high. heat, it is so hot insulation
until windings damage, drain off
burn and old oil and clean
insulation it. new oil
damage replaces it.
2 Temperature of air- 2a. Over load 2a. Poor powerfactor 2a. Decrease load and
cooled transformer and overload powerfactor
rises until serious correction
level.
2b. Not enough air 2b. Air circulating or 2b. Increase air
volume air blowing very circulating rate.
weak or block in or clean air pipe
air pipe
3. Temperature of 3a. Over load 3a. Poor powerfactor 3a. Decrease load and
water-cooled and overload powerfactor
transformer rises correction
until serious level.
3b. Not enough water 3b. Something like 3b. Water force
flow in pipe oil dirt block in applied, cleaning
pipe by soap clean to
oil and oil dirt,
coils are under oil
level.
3c. Oil dirt is stuck 3c. Transformer 3c. If oil dirt on pipes
on the cooling working in so less cannot remove,
pipes surface. temperature. disassemble the
Transformer temp cooling coils and
must not less than the coolest pipes
10deg C. to clean by
scratch method.
4. Explode sound in Neighbor wire layers Cooling coil surface of Test to transformer oil
transformer tank. of HV winding are in air cooled or oil if cannot get standard
short circuit. cooled transformer are level, check again and
in small holes or refill it.
leakage moisture go
inside, so transformer
temperature drop
under 10deg.C
Short circuit between Insulation drops or Replace to damage
HV winding and LV damage. coil.
winding. Switch on/off when
full load condition.
End part connection Change to damage

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 ELECTRICAL HAND BOOK 7
TROUBLE SHOOTING
of wire insulation coils and end parts'
trouble insulation should be
Actually that part replaced by thicker
insulation is 5 times size.
better than inner
parts.
Core construction not Sends back to
so nice. manufacturer and
repair it.
Transformer coils are It will become short
placed in not correct circuit, so repair and
position. re fitting.
No lightning Repair to damage
protection, so when coils, replace new
lightning times the coils.
effect of lightning Every transformer has
surge make it. lightning protection,
the lightning
protection are series
with choke coil,
reactor etc.
When storm coming, Replace damages coil
short circuit in line to and put thicker
line and short to insulation to end parts
transformer. of wire.
LV winding ground to By lightning strike, Replace damages coil
core. hit line to line and and put thicker
insulation weakness. insulation to end parts
of wire.
Send back to
manufacturer and
repair it
Short circuit on Oil mixed with Repair to terminal
terminal board moisture. board and repaint by
varnish.
It should separate oil
and moisture by filter.
Short circuit in HV or Damage in bushing. Replace to bushing.
LV bushing.
Not equal load Parallel operation to It must be same
sharing different characteristic characteristic
two transformers. transformer to parallel
operation, otherwise
put in reactance
between two
transformers.
Damage LV winding HV side in ground, Open to ground and
when there are no then repair to LV
ground neutral. winding.
Ground connection to
LV and HV neutral.
HV side in ground Open to ground and
and LV neutral then repair to LV
connect to ground. winding.
Ground connection to
LV and HV neutral

5. Different Ground in a phase Insulation drop or Open immediately to

temperature in a line to ground in line otherwise short
transformer which transformer. harzard in
has star neutral transformer, and then
ground find out the location
that ground coil and
insulation put in or
add in.
6. Different Ground somewhere to Same symptom likes Same manner as
temperature in a primary phase. above cause. above.
transformer which
has primary star -
secondary delta.
7. Different phase Ground in a phase of Insulation damage in Take off or cut out
voltage in a 3 phase star-delta transformer. line, ground where trouble found,
transformer. the other two phases somewhere in line, and then repair to
are 1.732 times bigger transformer insulation ground trouble,
drop. replace with new
insulators, bushings. If
trouble found in
winding, repair as re-

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 ELECTRICAL HAND BOOK 8
TROUBLE SHOOTING
winding.
A transformer bucking Its polarity opposite To check polarity to
or counter acts to among other, if it is get correct and then
other transformers. not repaired one or change polarity of
more transformers transformer which is
will be burned out. trouble.
8. Very less voltage Wrong ratio It is not correctly Raise up tapping
calculated connected to correct numbers to get until
ratio tapping. necessary voltage.
9. Very high voltage Wrong ratio Same symptom as Drop down tapping
calculated above numbers to get until
necessary voltage
Parallel connected to Change transformers
transformers which until same ratios to
were in different ratio get, if cannot adjust,
replace and use to
same ratio new
transformers

AUTO STEP-UP TRANSFORMER DESIGN(for Domestic use in Myanmar)

@Relationship in power Vs voltage and current
P=V x I
Where P = Power required in Watt.
V = Terminal supplied voltage (Volt)
I = Current (Ampere)

@Relationship in iron core cross sectional area Vs width and breadth

A=X x Y
Where A = Iron Core Cross Sectional Area in sq.-inch
X = Width of the Iron Core Cross Section in inch.
Y = Breadth of the Iron Core Cross Section in inch.

@Relationship between iron core c.s.a vs power output

A = SQRT(W)/5.58 OR A = 0.17 x SQRT(W)
Where A = Iron Core Cross Sectional Area in sq.-inch
W = Power Out put in Watt

@Relationship for core iron quality vs turns per volt.

• For good quality N = 8/A Where N = turns/volt, A = CSA in sq-in
• For fair quality N = 10/A
• For bad quality N = 12/A

@General Formulae for EMF

E = 4.44 BNFA x 10-8 Volt
Where E = EMF in volt
@Table for Current vs Wire SWG Gauge Selection
SWG Current Turns/inch Turns/sq-in SWG Current Turns/inch Turns/sq-in
1 141.4 3.1 - 24. 0.760 42.4 1789
2 119.6 3.6 - 25. 0.628 46.5 2070
3 99.8 4.0 -- 26. 0.510 51.5 2650
4 84.6 4.3 - 27. 0.422 56.5 3190
5 70.6 4.7 - 28. 0.344 62.5 3900
6 58.0 5.2 - 29. 0.290 67.6 4550
7 48.6 5.6 - 30. 0.242 74.6 5550
8 40.2 6.0 - 31. 0.212 79.4 6300
9 32.6 6.7 44.89 32. 0.184 85.7 7300
10 25.8 7.6 57.76 33. 0.156 91.7 8400
11 21.2 8.5 72.25 34. 0.132 100 10000
12 17.0 9.2 84.64 35. 0.110 109 12000
13 13.2 13.8 116.64 36. 0.090 120 14500
14 10.0 12.1 146.41 37. 0.072 135 18200
15 8.140 13.7 176.00 38. 0.056 151 22900
16 6.440 14.8 219.00 39. 0.042 175 30600
17 4.920 16.9 285.61 40. 0.036 180 35600
18 3.620 19.7 388.00 41. 0.030 2 43000
19 2.520 23.5 550.00 42. 0.024 227 51000
20 2.040 26.0 676.00 43. 0.020 256 65000
21 1.608 29.2 852.00 44. 0.016 285 81000
22 1.240 33.0 1089.00 45. 0.0122 322 104000
23 0.904 38.3 1513.00 46. 0.0090 377 142000

Designing Procedure for Auto Step-up Transformer in Residential use.

• Find the Total load in Power (Watt)
• Calculate to I in Ampere by Power formulae P = V x I Where V is standard terminal supply voltage.
• From I value in above table , find out the wire gauge size in SWG.

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 ELECTRICAL HAND BOOK 9
TROUBLE SHOOTING
• What is your iron core size in your hand or thinking the core size by rule of thumb.
• Calculate iron core CSA from formulae A = X" x Y"
• Depends on the iron core CSA, find out the turns per volt form N=8/A, 10/A or 12/A
• For 220V stable standard system, 80V should be at least point of input voltage in supply (primary side in
autotransformer). So decide the turns of required voltage tapping.
• Also find out the turns/layer.
• Draw the terminal schematic drawing for auto-step-up transformer.
• Decide that manual, semi-auto, fully auto control system to use in control.

DRAWING SIZE & ARRANGEMENT

( Referred to AutoCAD 12 for Windows, AutoCAD 13 for Windows & AutoCAD 14 )
Display Area on the Paper
Paper Size Display Area in mm Scale in inch
A0 1140 x 800
A1 795 x 560
A2 554 x 388
A3 380 x 265
A4 210 x 297 11.2
Scale Printing
1. Set in control panel setting range as 210 x 297mm A4 size
2. Unprinting area 160 top/ bottom / left / right
3. Set in print set up in ACAD
4. Scale to fit
1/4 ===> 1"~4' ====> 11.2 ===> 760.1466 (or) 63' 4-19/125"
1/8 ===> 1"~8' ====> 11.2 ===> 1520.2932
3/32"==> 3"~32'====> 11.2 ===> 2027.1104 (or) 168' 11-7/64"
Scale Multiply factor Arrow Ext. Ext. Dimensi Text Text Gap Toleranc
Size Line Line on line height e Height
Origin spacing
al
Offset
1/4" 4x1.414x11.2x12 4" 6" 6" 3/8" 6" 3/32" 1"
3/32" 32/3x1.414x11.2x12 1'-6" 1' 1' 6" 1' 3/32" 1"
1/32" 32x1.414x11.2x12 2' 2' 2' 3/8" 2' 4" 1"
3/16" 16/3x1.414x11.2x12 9" 1' 1' 49/128" 1' 3/32" 1"

ANALYZING MOTOR TROUBLE

Procedure for Analyzing Motor Trouble

1. Inspect the motor to detect mechanical Winding data

trouble as broken or cracked end plates, badly
1. Name plate data,
bent shaft, and broken or burned leads.
2. The number of poles
2. Test the motor for bearing trouble move up 3. The pitch of the coil ( the number of slots
and down , turn the rotor by hand, fuse burn that each coil spans )
out. 4. The number of turn in each coil.
5. The size of the wire of each winding
3. Whether or not the internal wires are 6. The kind of connection ( series or parallel )
touching the iron cores of the rotor or stator
7. The position of each winding in relation to
ground test using by test lamp or megger. other windings.
4. Running test to the motor - switch closed 8. The type of winding (whether hand, form of
few seconds. skein )
9. Slot insulation, both size and kind.
• Fuse blow 10. Number of slots.
• The winding may smoke
• The motor may rotate slowly or noisily.
• It may not turn all. Name plate data
1. Manufacturer's type and frame designation.
Repair to damage winding procedure. 2. Horse power out put.
3. Time rating.
Remove end plate and test to winding carefully.
4. Temperature.
1. Taking data. 5. RPM at full load.
2. Stripping the winding. 6. Frequency, cycles per second (Hertz)
3. Insulating the slots. 7. Number of phases.
4. Rewinding. 8. Voltage
5. Connecting the winding. 9. Full load amperes
6. Testing. 10. Code
7. Baking and and varnishing. 11. Design letter for integral HP motors

1. Taking data.

Page No. 9
 ELECTRICAL HAND BOOK 10
TROUBLE SHOOTING
12. For motor equipped with thermal
protection and for motor rated more than 1 h.p.
a type number.
13. Service factor.

2. Stripping the winding

• Remove the wedges.
• Varnish melting.
• Turn and wire size record.

3. Insulation the slots

• Magnet wire type and insulation
classes.
• Slot insulation (paper).

4. Rewinding
• Hand winding method.
• Form winding method.
• Skein winding method.

5. Winding Connection
• Series connection or parallel
connection.
• Splicing and taping.

6. Testing the winding

• Short
• Grounds
• Open circuit
• Incorrect connections.

7. Baking and Varnishing

• Baking Oven at 250 Deg. F 1 hour.
• Dipping the varnish.
• Soak in the varnish 1/2-hour.
• Air drying varnish - fractional h.p.
motor / Class A type thermal /
• Heated by 1/2 voltage to winding.
• Exposy resin or polyester varnish
poured.
• Winding heated by sending current
about 5 min.
• All time ½ hour.

Page No. 10
 ALTERNATOR
Alternator
Stationary Field & Rotating Armature Stationary Armature & Rotating Field
Small Capacity
Salient Pole
Large Diameter
Short Axial length Long axial length
Low Speed
ALTERNATOR TROUBLE SHOOTING & REPAIR
sr.no Fault Possible Case
1. Absolute temperature so Overload
high
Dirt or foreign particles block to
air inlet & outlet or filter in force
cooling air system.
Unbalance load in 3-phase
alternator.
2. Overheat in rotating Overload
winding
Over excitation when very low
power factor.
Something happens (fault) in
prime mover therefore slow in
speed & gives it over excitation.
Not enough filed winding
Over winding in AC-winding , so
over in DC volt.
3 Vibration & Overheat in There are short circuit turns in
rotating filed winding field winding, although it is so
{ Carefully check in log much rotor current , higher in
that means check in lagging power factor because it's
excitation ammeter ampere-turn is less.
reading, if it is in As in experience - End windings'
suddenly abnormal short circuit are happened as
means suddenly short following factors:-
circuit in winding} Big Alternators' cylindrical
rotors are many times in
start/stop
overheat and overcool depends
upon weather in surrounding or
other factors
centrifugal force
4 Spark in Slip-ring There are unbalance current
Overheat in Brushes sharing in brushes.
and Slip-ring 1. Unequal in brush pressure
2. Slip ring contain in different
type brushes or un-meshing
brushes use together.
3. Air-film under some brushes
Large Capacity
Cylindrical Pole
Small Diameter
High Speed
Repair Method
Release the mechanical power load in
motor, supplied by alternator.
Take off the no important feeder.
Cleaning to filters.
Re-share phase-current to get in balance.
Release the mechanical power load in
motor, supplied by alternator.
Take off the no important feeder.
Power factor correction
1. Capacitor fixing
2. Using synchronous motor : it is better
method because it can get mechanical
power and good power factor.
Find out & repair that what happen to slow
speed in revolution of machine.
Test run in no load to make sure that it is
fault happen in machine as vibration.
Vibration is happened that it is not fair in
magnetism.
When in standstill condition nothing
happen, but it is short circuit in running
condition.
see note(1)
Field winding should be not damage to take
care as following cautions:-
Overheat
Overload
So many times in start/stop
1. Equal pressure in every brush and
increase if necessary.
2. Use correct brushes as manufacturer's
advice. If in case use brasso to smooth
brushes surface for equal current
intensity.
Making small slot as length on brush's
 and overcurrent flow in surface for blow out dirt and get it in
other un-necessary brushes. good contact, also can get good cooling
Over contact voltage on brushes To omit this effect, making slot pattern like
surfaces because so many dirt on spiral grove.
it.
5 Over temperature in As current flowing direction for To omit this effect, must be change in
negative bronze, brass material more polarity as in time. Nothing failure in steel
ware and tear effect in negative ring.
brushes than positive brushes.
6 Unstable load current 6.1. Something failure in driving 6.1. To find out in external failure.
motor's rotor.
Over slip in belt
Problem in primemover's
governor
6.2. Sometime short circuit in 6.2. To find out in trouble and repair it.
rotating field Field AC/DC regulator fault happen
Sometime open circuit in
exciter.
Damage connection in
regulator rotating field.
6.3. Unbalance load like 6.3. Should not supply by single alternator
Furnace as in main.
or Welding set.
7 No electricity in Exciter fault
alternator 7.1. Problem in exciter /ac
winding
7.2. Problem in exciter /dc
winding
7.3. Problem in diode, voltage
regulator
.
7a. Open circuit in field winding 7a. Find out in location and repair it.
terminals or field regulator.
7b. Loosing in terminals or joint 7b. Find out in location and repair it
of regulator therefore shunt field
circuit resistance so much.
7c. More parts of filed winding 7c. Inspection, checking and repair it for
become outside so those damage windings or terminals.
short circuit in field coil or
terminals.
Other way short circuit
among external winding and
field winding.
7d. Residual magnetism loses. 7d. Take off the connection and supply by
battery in few or more minutes then re-
connect back as origin.
7e. Reverse in field winding 7e. Re-connect backs field winding and
run as over speed limit, if it require
short circuit to the armature to increase
excitation.
7f. Field coils or a field coil 7f. Checking and re -connect back as
reverse connection corrects in pole and polarity.
7g. Slow excitation because 7g. Checking and re -connect back as
wrong in field regulator corrects in regulator connection
terminals connection. terminals.
7h. Commutator & contact
resistance so mush

(i) Dirty in commutator or (i) Cleaning to commutator surface

dirty in rinse.
(ii) Not enough in brush (ii) Raise up to brush spring tension.
pressure
7i. After maintenance, 7i. Reposition in correct brush position.
 something wrong in brush
positions.
7j. Failure in rotating field
circuit
wrong in connection
open circuit in winding
not enough contact area on
slip-ring
7k. After maintenance, wrong
connection terminals in field
circuit.
7l. Not include in more parts of
excitation winding because
there are short or earth fault
in field system.
7m. Open circuit in stator
winding
8 Very low voltage Excitation defects
produce 8a. Very high resistance in
executor circuit.
8b. Reverse connection to field
coils or coils
8c. Wrong brush position
8d. After maintained, field coils
were wrongly connected as
series that means originally
parallel connection.
8e. Short circuit in coils or a
coil
8f. It is so big air gap , after
maintenance that means
wrongly fixed
8g. Remark - Not enough field
excitation otherwise it is AC
excitation winding so it's
taking voltage is as
transformer reaction.
Therefore it cannot take so
much voltage.
Eacless-->i less -->φ less--
>Ephless
8h. Very less in rpm.
8i. Short circuit in revolving
field winding connection
reverse in connection.
So much vibration.
8h. Most of the windings are
shorted circuit so field
winding is not included
8i. When it is repaired to
winding, reversibly and
7j. Find out failure and repair it.
7k. Inspection and correctly re-connect
back or re-assemble to get correct
poles.
7l. Inspection to part of winding which is
failure and repairs it.
7m. Using necessary testing methods to
know that where is it failure? and
repair it.
8a. Take off extra resistance by regulator
or wrong connection and poor contact
to repair it.
8b. Reconnect coils' terminals correctly.
8c. Reposition it
8d. Reconnect it.
8e. Repair to damage coils or coil.
8f. Reposition and refit back as correctly
to get it correctly.
8g. I=Power/Eph >> I so much >>winding
burn
8h. Increase in rpm up to correct speed by
major source to repair that means
governor.
8i. Find out the trouble and repair it.
Reconnect back to get correct pole
sequence
8h. Find out the trouble coil and repair it.
1. Measured resistance by
Ohmmeter
2. Supply fair reduce voltage to
stator ,so rotor winding got
induced emf and hot in
defective coil
3. Also find out short circuit
come out only in motor
running time.
8i. Checks in voltage as phase by phase
and find out wrongly connected coils
 wrongly connected to some
stator windings
9 Current suddenly Suddenly increase in load on
exceed and unstable in alternator, so the exciter unstable
phase then its' polarity in reverse and
decrease in flux as very short
time
10 Exciter polarity reverse Short circuit on the system so re-
close shunt field switch in very
short time(in second), therefore
rotor induced emf is reversed
with exciter shunt field.
11 Unstable in alternator 11a. So much capacitive load,
voltage. effect to increase voltage and
unstable in self excitation
and alternator.
11b.Induction motor loads are
suddenly increase and then
decrease, so filed decrease
and voltage decrease by
armature reaction
12 Unequal load sharing in There are different characteristic
parallel operation of in alternators and exciters
alternators.
13 Hunting in parallel 13a.One or more alternator/s
operation. prime mover in defects.
13b.Unstable steam pressure or
poor governor, so it is
mechanical impulse in prime
mover.
14 Circulating current in Combined two star points which
parallel operating are not same in characteristic.
alternators
15 Poor regulation in Unmatching regulator was
parallel operation wrongly installed .
e.g. Current coils terminals of
compound regulator were
reversibly connected so that over
excitation and more reactive
component KVAR
16 Suddenly voltage drop One phase is out of sequence in 3
when parallel operation phase system
in two generators
Note 1. Short circuit by centrifugal force can be tested by DC resistance measurement. Measurement should be start from
standstill to various rpm .If it is suddenly change in resistance to know as it is in short circuit. Also same way measure in pole
by pole to know which is defective.
Note 2. It should be fix necessary stability plate in exciter's field magnet. That means an iron sheet, smaller csa than pole csa,
is put between pole and yoke as magnetic circuit. Thickness and area of iron sheet is rule of thumb. Exciter's field switch must
be close otherwise residual flux will be loss.
Note 3. Stability test : Measure short circuit full load stator current excitation. Also measure open circuit normal voltage
excitation. Summation of above two is full load, zero lagging power factor load excitation for required voltage.
and reconnect back as correctly.
Position to brush ahead then it gets
enough increase field current and it gets
enough voltage and then stable in exciter
condition.
Otherwise series resistance adds to field
winding to get the stable in exciter
condition.
see. Remark 2.
Series field winding protect to be polarity
reverse, So it should use AVR and pilot
exciter, supply to main exciter and can get
stability and correct polarity.
11a. It should not supply to many capacitive
loads by an alternator.
11b.It can be voltage stability by necessary
voltage regulator. Some alternator's
rotor excitation must be increased in
very short period because of its
armature reactance natures.
It should change be excitation so watt less
load changed.
Adjust prime mover output and it can get
useful output power.
13a.Discuss with prime mover
manufacturer because of it is very poor
synchronism and hunting.
It is only prime mover manufacturer
responsibility.
13a.Same as above
Decrease fair current by reactor fixing.
Earthing in parallel operated governors, so
it happens that circulating current by
harmonic frequency.
AVRs connection should be as followed
1. Current coil in one phase.
2. Voltage coil in other two phases
It can get voltage and powerfactor in same
with one to another.
JK contactor of field exciters are series
connection so it share with same field
excitation therefore take off a generator a
while from synchronism. But if it correct
one ,system is OK, otherwise black out.
Note 4. Governors should be same characteristic so it can get useful load sharing.
Alternators should have same voltage regulation .Main mechanical force supply to filed regulators can get same voltage curves
of exciter. It should be same voltage regulation. It should be same steps in voltage regulator.

Parallel Operation Alternators

The reasons for parallel operation
1. It is the best efficiency in 75% to 100% load, so it can get the cost per unit amount for generation and good in load factor.
2. Small machines can be matained easily that means some are running , some standby and some overhauling. If it has good
rotation program for maintenance can avoid the major damage and continuously supply.
3. It is easy to upgrade the generation station to supply higher demand.
Parallel operation procedure
1. Correct phase sequence connection that mean correct in RYB or 123.
2. Same or equal frequencies of the alternators.
3. Busbar voltage and Generator paralleled voltage must be equal. It can get adjust to field excitation at pre mark speed of
rotation.
4. It must know that exact time at synchronizing It can be known by synchroscope, dark lamp method, bright lamp method,
one dark two bright lamp method.
 DC MOTOR TROUBLE SHOOTING & REPAIR

Sr.No. Fault Possible Case Reminds

1. Motor not running 1.1 Voltage loss at motor 1.1.1.Check main switch, if fuse burn out,
terminals replace new one.
1.1.2. If it is not fuse blown, check starter
starting resistors. It may be opened at
resistance section.
1.2 Overload 1.2.1. Run motor in no load that means
take off belt from motor pulley, if it is
gear motor take it out and run no load. If
motor run in smoothly ,change to bigger
h.p. motor
1.3 Armature short- 1.3.1. Check and see whether good
circuit or open circuit. contact in brush and commutator or not.
1.3.2. If it is in good contact check
armature coils.
1.4 Field circuit open or 1.4.1 Check field circuit and field coils
short. as one by one.
1.4.2 Off load and turn pulley by hand if
it is not running, it may be bearing
frozen, not correct position.
1.4.3 Check air gap between armature
and pole.
2. Motor run, but 2.1. No magnetic force in 2.1.1. Check open circuit in field coil, it
starter off many holding coil or very weak may be field coils terminals open or lose
short times magnetism. connection.
2.1.2. Check no volt release coil working
or not
2.2. Not enough torque 2.2.1. Check supply voltage ( rated or less
for overload. 2.2.2. Decrease load and run to motor, it
may be not correct size (small) hp.
3. Suddenly stop when 3.1 Electricity failure 3.1.1 Check main switch.
motor was running. 3.1.2 Check starter protection devices.
3.2 Overload 3.2.1 Check mechanical part, it may be
suddenly increased load
4 Very noisy 4.1 Loose in shaft sleeve 4.1.1. Check it is straight motor pulley
bearing and mechanical driven (load) part.
4.2 Over vibrating or 4.2.1 Check it is balance weight on
Excessive vibration armature
4.2.2 Check loose bearing
4.3 Armature winding's 4.3.1 Check every coils, every slots,
wedges are loose every wedges
4.3.2 Check binding strings which tie
to coils are broken or not.
5. Over heat in 5.1 Brushes are not 5.1.1 Dismantle the brushes from their
commutator correct position holder and adjust the placing.
5.2 Over pressure in 5.2.1 Check spring pressure to every
brushes springs. brushes and make any adjustment
6. Armature overheat 6.1 Motor overload 6.1.1 Decrease load
6.1.2 Change to bigger capacity motor
6.2 Something blocks in 6.2.1 Check ground in armature by
armature core ventilation. instruments. ( Megger, growler tester )
6.2.2 Check short circuit in armature by
instruments.( Megger, growler tester )
7. Overheat in field 7.1 Turn short in field • Disconnect field coils' connection
coils coils • Measure each coils resistance. It
must be the same value.
• Low value coil's resistance means
turn short.
• If a little turn short must be painted
insulation or varnish

8. Motor runs very 8.1 Short circuit in
slowly armature or commutator.
Carbon particle stuck
on commutator.
8.2 Pole shoe and
armature touched when it
is running.
8.3 Over press brushes
and commutator.
9. Sparking in brushes 9.1 Out of position in
commutators
9.2 Brushes are out of
M.N.A or without M.N.A
9.3 Overload
10. Overheat in bearing 10.1 Grease frozen in
bearing housing
10.2 Not enough
lubrication in bearing.
10.3 Over tension in belt
or chain.
• If very harzard damage in coil to
rewinding.
8.1.1 Check short circuit in which coil of
armature.
8.1.2 Also check short circuit in which
commutator segment.
Can test by means of megger or external
glower.
8.2.1 Take out shin iron strips which are
under the poles and adjust to get correct
clearance between pole shoe and
armature.
8.3.1 Check it is become rough surface
on commutator's face.
8.3.2 Check loose in brush holder.
8.3.3. Check spring pressure correct or
not.
9.1.1 Check spring pressure
9.1.2 Check it is smooth surface on
commutator face.
9.1.3 Check brushes and brushes holders
position correct or not.
9.2.1 Find out Neutral point and
reposition brushes.
9.3.1 Decrease load
9.3.2 Replace bigger capacity motor.
10.1 Read instruction of manufacturer
and follow it.
10.2.1 Read instruction of manufacturer
and follow it.
10.2.2 Check it is correct lubricating oil
or not and put in.
10.3 Decrease tension.

CONTACTOR THEORY
Contactor Theory
1. Normal Using : Surface of the contactor roughness depends upon the ratio of interruption and closing number of times that
means closing at 5 times of rated current , interruption at 2million times of rated current and so many time interruption and
closing contactors.
It is very little chance to compare that deformation in edge of the contactor by wear and tear.
Until color of contactor change to dark blue color, it is no problem so can use continuously.

2. Closing/Interruption at Overcurrent : Surface of roughness and deformation of contactor can be come out when 2 times of
rated current. Edges of the contactor spread out . It can see that silver spot on the dark blue contactor surface, but it is no need to
do any maintenance.

3. Suddenly and So many times open and closing at Inrush Current: When it is motor inching time that means speed up and
little time running, is 5 times bigger than rated current, contactor are closed and/or open can cause following defects or
symptoms
3.1 wear and tear
3.2 dis-uniforming
3.3 Silver alloy melts and spread out
3.4 Silver melted liquid drop down in fixed contact
3.5 many wear tear at the top of the moving contact
3.6 it can see melted silver uniformly spread on the base plate of moving contact
3.7 Also it can see blue color silver sulfate, well known that silver brightness parts
3.8 crack lines on the contactor when it is open/close time so much.
Find out the basic trouble and maintain as so many times to get correctly.
4. Close/Open at Over rush current : Contactors are open/close at 10 times of rated current can get following defects or
symptoms.
4.1 it is rising that surface roughness.
4.2 All surface become brightly silver color.
4.3 It can see arcing amount.
It may be interrupted at harzard severe time like short circuit.
Find out the basic trouble/reason and remove it furthermore normal maintaining.

5. Un-completely Closing : There are following three reason of the contactors' nature.
5.1 Less voltage and incompletely closing
5.2 Under voltage supply and incompletely closing contact symptom
5.3 Wear and tear for contactor vibrating.

5.1 Less voltage and incompletely closing: It can get enough magnetic attractive force that 85% of rated voltage. But supply
side drops severely causes very low magnetic attractive force and happen that incompletely closing of contactor.

Also motor vibrating can get that loss voltage and contactor vibrated. So that contactor closes and opens so fast and contact
burnt by arcing heat.

Although supply voltage enough or complete , wire so long and/or under size(very small, very high resistance) can also be
incompletely closing.

It is bigger than 5 times of rated current when 3 phase induction motor direct starting time. If it is used very small size wire in
circuit, terminal voltage of magnetic coil may be lower than 85% of rated supply voltage. So it's voltage loss cause can not close
completely and can see contacts vibration.

Normally motor start to run slowly and smoothly, very short time current flow like that and then starting time finish and current
drop until normal rated current. In this way voltage becomes normal rated voltage and electro magnetic contactors are in enough
voltage and continue.
Sometime it may be combine effect that supply voltage drop and wire size so small.

5.2 Under voltage supply and incompletely closing contact symptom : Wear and tear at contact top part that means it is can
not move to top part until contactor are suppressed.
Wear and tear the whole surface.
Especially center area roughness is higher.
It can see specially un-uniforming.
Edge of the contacts becomes like flowers.
Sometime base plate of the contact burn by heat flow by contact.
Sometime it is change in color.

5.3 Wear and tear for contactor vibrating: A electro magnetic contactor performs together with auxiliary relay, plugging
relay, and thermostat. So if their vibrations effect to contactor vibration by voltage unstable. Until good condition of contactor is
unstable close and vibrate in very short period and then completely close.
It is bigger arcing in starting than stopping.

6. Contact Changing or Replacing: Normally it is assume that contact changing time by daily using times and number of days.
But it should not decide that normal performing facts.
It should decide contact changing time by wiping drop and amount of wear and tear.
Normally top part of contact wear and tear is small so that it must decide by wipe condition.
If something special using also consider that top part wearing.

7. Wipe : Moving of contact base starts to end. Until contact moving finished, base continuously moves therefore spring
pressure increase until base stop. The moving force can get from electro magnet.
When contact wear , wipe less and pressure drop.
Rated lowest level of wipe value is 0.3mm or 1mm or 1.5mm to 2mm etc.

Note: Arc shield should change new one when contact changing otherwise short circuit in normal condition.
If it rust on contact of electromagnet surface, clean by dry clothes . Don't scratch surface, otherwise it can be humming.
Normal rusting also does normal performance.
If it wants to stop long time, it is to coat little by low viscosity transformer oil to prevent rusting.
It is not stick dirt on electromagnet axis by blower. Otherwise it is humming by dirt on surface.
 CONTACTORS TROUBLE SHOOTING
Sr.No Problem Relation Possible Case To Operate Remark
1. Contact not Coil very hot 1.1. Supply voltage Discuss with • Voltage drop so high by not only loa
close so low Electrical supply but also current.
department. • Power line very long or very small s
1.2. Unstable of wire.
supply voltage

1.3. Volt variation

so much in circuit.

1.4. Damage 1.4. Repair it or

(mold etc.) change new one.
1.5. Loose 1.5. Reconnect back If it tight nicely, it cannot loose anymore
connection tightly.
1.6 Loose contact 1.6 Repair it or
change new one.
1.7 Contact 1.7 Repair it or Lousy float switch, plugging switch can
vibrate change new one. made vibration and misunderstanding to
electro magnetic starter.
1.8 Relay operated 1.8 Find troubles Supervisor never experience trouble is in
and maintain it. misunderstanding assumes that overload
relay operates, and can not switch on.
Press reset buttons and starts again.
1.9 Line opens or 1.9 Correction to It is not so easy to find out the trouble, s
ground to operate right circuit. that misunderstand the basic reason.
circuit.
1.10 Wrong 1.10 Re arrange that
connection in to get correct circuit
circuit connection
2 Contact vibrate • Melting 2.1 Supply voltage Discuss Electricity
and mis very low. Supply Department.
positioning
• Informally 2.2 Unstable Over volt drop by load current + starting
wear and supply voltage. current.
tear.
2.3 Unstable Power line very long or very small wire
circuit voltage causes volt drop in starting time.
2.4 Loose Connect firmly. If it is firmly tighten, it can't loose wash
connection and spring anymore.
2.5 Contact vibrate Repair it or change Starter may misunderstand that effects o
to new good one. lousy float switch, plugging relay etc.

3. Over attractive 3.1 Over voltage 3.1 Use correctly.

force. and frequency.
3.2 Open line or 3.2 Repair it or
short circuit in coil. change new good
one.
3.3 Dirt in 3.3 If possible It may be explode when dirt so many ins
contactor unit assemble in dirt free Also problem in moisture and dirt mixin
area or use dirt proof environment.
type
4. Noisy in 4.1 Supply voltage 4.1 Discuss with
operation. very low. Electricity supplier
4.2 Over voltage 4.2 Use correctly.
or frequency.
4.3 Line open or 4.3 Repair it or
short circuit in coil. change new good
one.
5. Contact melting Circuit not 5.1 So many 5.1 Discuss with 5.1 It may be possible for plugging and
and mis- open contacts operating company agent. inching operation nature.
 positioning times
5.2 Short circuit 5.2 Find out basic
at load side.(fuse problem and repair
not include) it, also use good
enough protective
fuses.
6. Informally wear 6.1 Operated 6.1 Use correctly.
and tear. voltage or
frequency not
corrects.
6.2 Phase out, run 6.2 Discuss with sale 6.2 To select that first class of interrupt
reverse a bit and agent or technical in plugging and inching.
over rated current agent.
running.
6.3 So much times 6.2 Discuss with sale 6.3 Over plugging and inching effect to
open and close. agent or technical contactors.
agent.
6.4 Oil dirt stuck 6.4 Take care about wiring for oil usin
on the contact machine.
surface.
6.5 Short circuit 6.5 Find out the 6.5 Thimble overload relays can not pro
at load side (fuse primary problem and to short circuit. Also wire fuses are weak
not include in short repair it and use blow out so it can not interrupt the circu
ckt) enough fuse size. that means it is assumption that no fuse
include in circuit
7. Circuit or • operate 7.1 Damage mold 7.1 Repair it or
contact not very easy etc. change new good
open • Heater 7.2 Iron core one. 7.2 Mechanical life time finished
burn out clearance so small
(mold)
7.3 Dirt inside 7.3.1 Fixing in dirt 7.3.1 If textile factory area, dirt inside
contactor unit. frees area or use dirt contactor can be exploded also the facto
proof type. that moisture filled dirt can get the prob
7.4 Contactor's 7.4.1 Fixing in dirt 7.4.1 Machine that oil using should tak
iron surface oil dirt free area or use dirt care about wiring connection, and wirin
stuck proof type
8. Contact open • Very easy 8.1 Very little core 8.1 Repair it or 8.1 Mechanical life time finished
time very long to perform clearance change good new one
• Heater
burns out 8.2 Contactor's iron 8.2 Fixing in dirt
that means surface oil dirt frees area or use dirt
very hot stuck proof type.
mold unit.
9. Short circuit in 9.1 Dirt inside in 9.1 Fixing in dirt free 9.1 If textile factory area, dirt inside
phase contact contactor unit area or use dirt proof contactor can be exploded also the facto
type that moisture filled dirt can get the prob
9.2 Over closing 9.2 Discuss with 9.2 Plugging and inching operations ca
time in contactor manufacturer's agent damage to contactor.
9.3 Mold damage 9.3 Repair it or
change new good
one.
9.4 Other 9.4 Discuss with 9.4 It is very complex in control equipm
operating circuit manufacturer's agent so not very easy to find the problem
trouble therefore it can miss the main reason.
10. Thermal OL 10.1 Over closing 10.1 Discuss with 10.1 Plugging and inching operations ca
very easy to time in contactor manufacturer's agent damage to contactor.
work
10.2 Very long 10.2 Discuss with 10.2 Like fan, pump or car
time taking in manufacturer's agent
starting time
10.3 Over 10.3 Re do it 10.3 Calibrate as load limit, special sca
calibration to relay. correctly. calibrating should be mark as proportion
 10.4 Contactor fix 10.4 To fix at low 10.4 It is no problem for 1mm/1.200mi
at Very vibrate vibrating or no vibrating place.
place vibrating places.
10.5 Overload for 10.5 Find out the 10.5 Press reset for contactor crazy.
contactor trouble and repair it.
11. Thermal 11.1 Over 11.1 Re do it 11.1 Calibrate as load limit, special scal
overload no calibrating correctly. calibrating should be mark as proportion
working
11.2 Other 11.2 Discuss with 11.2 It is very complex in control equipm
operating circuit manufacturer's agent so not very easy to find the problem
trouble therefore it can miss the main reason
12. Heater burn out 12.1 Over work for 12.1 Discuss with 12.1 Plugging and inching operations ca
that means contactors. manufacturer's agent damage to contactor.
mold very hot.
It is thermal OL
relay problem
12.2 Short circuit 12.2. Find out the 12.2 Thermal OL relay can not protect
at load side that main reason and use short circuit. Wire fuse is low explosive
means not include reliable fuse type and that it can not blow out, therefore it is no
fuse. size include fuse in circuit.
• It should be change contactor that 2/3 of the contactor's silver coated wearied.
• It is sure damage with stuck that it only left Cu contacts.

MAGNETIC DISC BRAKE TOUBLESHOOTING

Sr.No. Trouble Cause
1. Not attract to armature 1.1 No terminal voltage or
or a little attract it. not enough very low in
terminal voltage.
1.2 Coil broke
1.3 Foreign materials are
place in armature and core
surface
1.4 Very big airgap
2. Armature cannot pick 2.1 Electricity cannot stop
off.
2.2 It is not smoothly turn
armature or lining holder.
2.3 Foreign material
inside.
2.4 Internal burning
2.5 Over voltage.
3. Magnetic coil burns 3.1 Short circuit in coil
out.
3.2 Counter voltage come
out
3.3 Slip and overheat.
3.4 Over heat in idling
torque.
3.5 Very low brake torque
Remedy
1.1 Check out the electric circuit and repair it.
1.2 Troubleshooting and repair it.
1.3 Clean it
1.4 Measure and re-calibrate back
2.1 Check out the electricity and repair it.
2.2 Dismantle it and release the parts which are over
tightened.
2.3 Dismantle and clean it.
2.4 Dismantle and check it out, if it very difficult to repair
replace good new one.
2.5 Check out the circuit and correct it.
3.1 Change new brake or new coil.
3.2.1 Check reverse voltage protecting resistor and repair i
damage.
3.2.2 Change brake.
Check the brake and find out the trouble as follows.
3.3.1 Armature attraction.
3.3.2 Low brake torque or very less brake torque.
3.3.3 Other type load using or not.
3.3.4 Many time performing need it or not.
3.3.5 Overlap motor and brake torque.
3.3.6 Lining burns out.
3.4. Recalibrate back to surface clearance.
Check it out as follows
3.5.1 Very big gap
3.5.2 Very weak in spring pressure.
3.5.3 It is not proper fitting.
3.5.4 Wrong selection brake size
3.5.5 Lining wet by oil.
4. Over slip or it cannot 4.1 Vary in load condition Check it out as follows
perform fast. 4.1.1 Load increase by 6D2
4.1.2 Increase speed rpm
4.1.3 Increase in repulsion force
4.2 Lining burn out 4.2 Find out the basic reason and change the lining.
4.3 Overlap with motor and 4.3 Check the basic reason and if it needs time different
bake torque between motor and brake.
4.5 Slip and overheat 4.5 Check out similar manner
4.6 Short circuit in coil. 4.6 Change new brake or coil.
5. Very hot brake 5.1 Very high terminal 5.1 Check it out the electric circuit and repair it.
housing. voltage
5.2 Overheat at normal no 5.2 Check out surface clearance and adjust it.
load
5.3 Wear and tear in brake 5.3 If it is possible repair it otherwise change new good on
housing thread and friction
disc.
6. It is too heavy to turn 6.1 Catch by brake 6.2 Release it
to friction disc
6.2 Spread out the thread 6.2 Cool it and turn it.

CAPACITOR MOTOR

Analyzing Motor Trouble

1. Inspect the motor for mechanical defects.

2. Test the motor for bearing troubles.
3. Test for ground, shorts.
4. Running test for noise, speed etc.
5. Capacitor must be tested

Rewinding
1. Taking data.
2. Stripping the winding
3. Insulating the slots.
4. Rewinding
5. Connects the winding.
6. Testing.
7. Braking and varnishing.

Common Reason for Capacitor Failure

1. Stuck or fused contacts on the switch on relay.
Result : Continuous application of voltage to the capacitor.
2. Worn or frozen bearings on the motor.
3. Excessive load on the motor.
Result : this prevents the motor from starting or from reaching full speed.
4. Incorrect capacitor rating.
Reason: Too large or too small a capacitor will produce a decrease in the starting torque.
5. Incorrect voltage rating of the capacitor.
notice: the voltage rating of the capacitor is much higher than the voltage rating of the motor, higher voltage capacitors
can be used to replace units with lower voltage ratings.
6. Lower line voltage.
Reason : low line voltage into the motor may cause the motor to continue running on the starting winding capacitor in
the circuit longer than permitted by its maximum duty cycle.
7. Shorted capacitor case.

Testing the capacitor

1. Fuse burn out test for shorted capacitor. 10A fuse across 115V, 60Hz power line .
2. Shorted by screwdriver.
3. Capacity test : Using ac voltmeter (||) & ac ammeter (series).
Capacity in uF = 159300 x Amperes / (Frequency x Volts)
4. Test for open : Using ammeter.
5. Test for shorts : Fuse burn out
Using test lamp in series
6. Test for Ground : Using test lamp.
7. Test for winding : * Grounds test
• Shorts test
• Opens test
• Reverse test.

Sr.no. Trouble Possible Case Cause Remedy

1. The Capacitor start 1. Defective Capacitor. Same as the 1.Test the capacitor.
motor fails to start split phase
motor.
2. Burn out fuse -----||------ 2. To find cause.
3. Opens windings -----||------ 3. Test for open using
test lamp.
4. Centrifugal switch -----||------ 4. Exchange.
5. Shorted winding -----||------ 5. Short test
6. Worn bearing -----||------ 6. Exchange
7. Overload -----||------ 7. Search
2. The motor hums and 1. Defective capacitor starting * Test Capacitor
then blows a fuse short. winding
shortly after current circuit will * Replace capacitor
is applied. be in
2. Defects capacitor opens operative
and motor
3. Loss of capacity not starting

• Permanent split capacitor motor expects the centrifugal switch will not be encountered.

Two-value Capacitor Motor

Sr.no. Trouble Possible Case Cause Remedy
* Electrolytic capacitor Prevent the starting Starting capacitor should be replaced.
defective. or
Not run perfectly

• Running capacitor failure with slightly lowered efficiency.

Two-value Capacitor -transformer Motor

Sr.no. Symptom Possible Cause Cause Remedy
1. Fail to run Defective capacitor - Capacitor or To remove the transformer & replace it with an
transformer unit. transformer electrolytic capacitor.
both or one
may break
down.
2. Efficiency slightly Lower the capacity. Difficult to * New capacitor change and see carefully
less and not run as determine. * Measure by ammeter if torque is the highest, t
quietly. lowest current in flow.

General trouble and Symptom for Capacitor Motor

Sr.no. Symptom/Trouble Possible Case
1. Poor Starting Torque or (a) Defective Capacitor
 starts with difficulty
2. The Fuse Burn out when
current is applied to the
motor
3. The motor hums but
doesn't run.
4. Smoke from a motor
while running
5. Higher temperature than
normal temperature
6. Higher than normal speed
7 Starting torque less
8. Slower than normal speed
(b) Worn Bearing
(c) Shorted winding
(d) Wrong connections
(a) Shorted winding
(b) Started capacitor
(c) Open winding
(d) Grounded winding
(e) Overloaded
(f) Badly worn bearings
(g) Defective centrifugal switch
(h) Wrong in pole connection
(a) Defective capacitor
(b) Open/Short starting or running winding
Overload
(d) Miss alignment in rotor (Rotor apmif;ae^cif;)
(e) Miss alignment in shaft (Shaft aumufae^cif;)
(f) Bearing so tight. (Bearing }uyfae^cif;)
(g) End plate miss position (End plate txdkifrus^cif;)
(a) Shorted windings
Failure of centrifugal switch to open starting winding circuit.
(e) Bearing trouble.
(f) Overload
(g) Defective auto transformer.
(a) Winding turn wrong (less winding turns)
(b) Winding wire size so small (Checking as table 3.)
Tight with rotor and stator
(e) So less in grease in bearing
(a) Wrong in pole connection or shorted
(b) Over supply voltage
(a) Check starting capacitor value
(b) Starting winding turn short
Overload
(a) Starting winding include running time by centrifugal switch.
(b) Wrong pole connection or Shorted.
Bearing clearance. see table 1.

SPLIT PHASE INDUCTION MOTOR

Motor Testing
Grounds : 1. Bolt of the end plate tight to winding and winding damage.
2. Windings and slot edge tight, when windings were placed.
3. Centrifugal switch ground to end plate , test by test lamp.

Open Circuit : 1. Loose connection or dirty connection.

2. Wire broken.
3. Centrifugal switch open, tests by test lamp.

Short Circuit : 1. Windings are very hardly pressed inside the slots and very hardly tightened until cover enamel damage.
2. Excessive heat by overload symptom : Smoke from windings and overcurrent in noload.
Testing Procedure : 1. Motor run in short time and find out that which winding is the hottest.
2. Use internal growler.
3. V drops test.
4. Measure field strength by iron strip.
5. Use ammeter
Reverse or Rotation : 1. The compass method.
2. The nail method.

Sr.no. Trouble Possible Case Test Method/Reason Remedy

1. Motor fail to start 1.1 Open running Testing the winding with Repair by rewinding if necessary.
coil test lamp.
1.2 Open starting 1.2.1 To connect the • May be repaired
coil motor to power line. by splicing if it
An open circuit starting • readily accessibly Rewinding is
winding will cause to the necessary if the coil is burned or severely dam
motor to hum • . To test the running winding for any
defects before replacing the starting winding o
1.2.2 Turn the rotor by
manual and switch
turn on, if motor continue
to run the trouble is
starting winding open

1.2.3 To use the test lamp

c.w switch open or
starting winding open.
First : Centrifugal switch
test.
Second : Starting
winding test.
1.3 Grounded 1.3.1 Fuse blow when 2 • Exchange the winding.
winding or more ground or
smoke • Insulation adding for small case.
1.3.2 Test lamp method

1.3.3 Use internal glower.

1.4 Burned or 1.4.1 Fuse blown • In many case only stating winding
shorted will be burned and need to rewind
winding 1.4.2 The winding will
smoke. • The running winding should be
tested before install the new starting. winding
1.4.3 Smell out and its
burned appearance
1.5 Open circuit 1.5.1 Overload • If the contact points are in bad condition
OLs devices 1.5.2 Too much current should be replaced with new ones.
(which connect flow through
series with motor) winding
1.5.3 The contacts are
examined for dirty,
defective or burned
points.
1.6 Excessive over 1.6 By connecting an • Cut out the overload and search for the ov
load ammeter in the ckt source & repair it.
<snap around volt,
ammeter, ohmmeter can
be used > A short
winding cause large
reading.
1.7 Worn or tight 1.7.1 To move the shaft • New bearings are required.
bearing. up and down by • Sleeve bearing is removed by means of ar
hand. some other press/new sleeve bearing repla
1.7.2 A small amount of • Motor is disassembled so that the rotor is
plays the bearing low
in one end plate.
rotor touch stator.
1.7.3 Sludge may • It may be reconditioned to its original rou
prevent an up and and smoothness by turning it in lathe
down motion of (metallization method used by forcing mo
 shaft. metal on it )
1.7.4 The shaft of rotor
is worn.

1.7.5 Frozen bearing • Loose to shaft by blow touch and then rep
(little grease in bearing so bearing.
molten by bearing heat)
1.8. End plate 1.8.1 The bearing is out • If end plate does not fit, all screwed shoul
improperly of alignment. loosened and each one tightened a little a
mounted. 1.8.2 The rotor turned by and drawing the plate evenly and securely
hand difficulty or not stator. In assembling first screw on, adjac
at all. on not tightly first and step by step tight.
1.8.3 Using mallet
hammer or lead
hammer and listen
The sound solid.
1.9 Bent rotor 1.9.1 Rotor doesn't turn • Rotor is removed from stator and placed i
shaft. easily by hand. (see in page 45.)
2 Motor run slower 2.1 Short circuit in 2.1.1 To run at a lower • To find the short and after it is found.
than normal speed running winding. speed. • Insulate it if possible.
2.1.2 Humming or • If it cannot be insulated, rewind the coil o
growling noise
entire winding.
2.1.3 The pole contains
the short will usually
become excessive hot
and smokes.
2.1.4 To locate the
shorted pole by an
internal glower is
used.
2.1.5 Pole may be located
by merely feeling for
the hot coil.
2.2 Starting 2.2.1. Same symptom for • Replace new c.w switch.
winding shorted running • Place fiber washer as correct position.
remains in the winding.
circuit. 2.2.2. Take off starting
winding and run it, if
cw s/w ok and run
properly means
starting winding not
properly working.
2.2.3. Contact points
were welded or stuck.
2.2.4. Fiber washer is
not proper position
on the shaft.
2.3. Reversed 2.3.1 Incorrect polarity. • When the improper polarity is located, th
running winding 2.3.2 Growling noise. wire of the pole are disconnected, reverse
poles. 2.3.3 Each pole tested by reconnected.
compass or nail test.
2.4. Other incorrect 2.4.1 Induced current to • To connect all poles exactly as required by
stator connections. flow in the pole coils
overheated, smoke and
burn out.
2.5 Worn in 2.5.1 Noisy in operation. • Same as upper worn bearing case.
bearing 2.5.2 Sluggish in
rotation.
2.5.3 Rotor rubs against
the stator while
running.
2.5.4 Motor shaft moved
up and down test.
 2.6 Loose rotor bars 2.6.1 The motor runs • Solder or welded to the end rings.
with reduced power. • Rotor with a die cast aluminum squirrel
2.6.2 Growling noise. • Cage does not have this defect.
2.6.3 Visual inspection.
2.6.4 Using armature
glower (or external
glower) flicker of the
series lamp indicates
open bar.
3 Motor runs hot 3.1 Shorted winding 3.1.1 Shorted pole will • Can be repaired and insulated the pole.
become excessive • The entire winding must be rewound.
hot.
3.1.2 Growling noise.
3.1.3 Testing shorts for
locate and short
circuit exists.
3.2 Grounded 3.2.1 Two or more ground • Re-insulating if possible.
winding is equal to short. • If impossible the grounded pole must be r
3.2.2 To run very hot. • If one point ground immediately repair is
3.2.3 Severe damage.
essential.
3.2.4 Use test lamp.
3.3 Short circuit 3.3.1 Will be burn out • The starting
between running the starting winding . winding is moved away from running winding
and starting • Winding and various places in the stator .
winding. 3.3.2 Use test lamp to shorted point is moved, the lamp will flic
starting winding terminal out.
and running winding • Use short point method to find the locatio
leads.
cannot use other method as take off startin
winding and find out.
• A strip of varnish cambric or Armo paper
between two windings.
3.4 Worn bearing. 3.4.1 Rotor touches to • Polish surface on it.
stator. • If rubbing against the stator, replacing the
3.4.2 Over heat when it bearing.
is just run.
3.4.3 Move rotor shaft
up and down.
3.5 Overload 3.5.1 Draw more than • The load should be reduced.
rated current . • Motor replaced with large one.
3.5.2 Procedure
excessive heat.
3.5.3 Ammeter test.
4. Motor runs noisily 4.1 Shored winding. |
that means unusual 4.2 Poles are |
amount of noise. connected | Produce magnetic hum Follow above methods.
improperly |
4.3 Loose rotor bar |
4.4 Worn bearing Allow the rotor to rub Follow above methods
against the stator.
4.5 Worn 4.5.1 Some parts of • Disassemble rotor and check centrifugal s
centrifugal switch centrifugal switch are not which you suspected.
separate in high speed, so • Repair the damage part.
it is touch to rotor and • If cannot repair replace by new one..
noise.
4.5.2 Loose member of
rotating part hit or rubs to
one part of motor.
4.6 Too much end Something plays more Put Fiber washer in require place of rotor shaf
play.. than 1/64" become noise.
4.7. Foreign It may be pieces of wire Disassemble motor and remove by pliers or sc
material in rotor. or insulation touch to driver carefully that its don't damage the wind
rotor and it makes noise.
 POLYPHASE INDUCTION MOTOR
#Testing

*Grounds Test * Disconnect the star point for each winding.

• Disconnected the jumpers between group of the coil windings.
• Opening the coil splices
• Search ground.
• Reinsulated the slot or new coil in the stator.

*Open Circuit Test

Break in the coil.
• Loose connection at the splices or jumpers.
• Use test lamp and determine phase open.
• Reconnected and soldered and tape.

*Shorted Circuit Test * Use internal growler.

• Operate the motor for a few minutes. Search for the hottest coil group.
• By means of ammeter (clip on type motor) in each phase (balance test)
• Higher reading phase is shorted.

*Reverse Test * Reverse coil - Compass needle method.

• Reverse coil group - Compass needle method.
• Reverse phases - Compass needle method.

Sr.no. Symptom/Trouble Possible Case

1. Fails to Start 1.1.Burn out Fuse
1.2.Worn bearings.
1.3.Over load
1.4.Open phase.
1.5.Shorted coil or group
1.6.Loose rotor bars.
1.7.Wrong internal connection.
1.8.Frozen bearing.
1.9.Defective controller.
1.10.Grounded windings
.
2. Not run properly 2.1. Burn out Fuse.
2.2. Worn bearings.
2.3. Shorted coils
2.4. Reversed phase.
2.5. Open phase
2.6. Open parallel connection.
2.7. Grounded windings.
2.8. Loose rotor bars.
2.9. Incorrect voltage or frequency.

3. Runs slowly. 3.1. Shorted coils or groups.

3.2. Reversed coils or group.
3.3. Worn bearing.
3.4. Overload.
3.5. Wrong connection (reversed phase).
3.6. Loose rotor bars.

4. Excessively hot. 4.1.Overload.

 4.2.Worn bearing
4.3.Tight bearing.
4.4.Shorted coil or group.
4.5.Motor running on single phase.
4.6.Loose rotor bars.
#Remark
Burn Out Fuse: * Remove fuse.
• Test with test lamp ( light means good, no light means bad )
• Don't remove fuse.
• Switch closes and test with test lamp. ( light means bad, no light means good )
• Winding become very hot and noisy and not pulls the load.
@ Remedy : Locate and replace the defective fuses.

Worn Bearings:
@ Cause :* Rotor will ride on the stator and cause noisy operation.
• If bearing are so worn rotor rest firmly on the stator and impossible to run.

@ Check: * Try moving the shaft up and down.

• Remove and inspects for the rotor for smooth, worn spots.
@ Remedy: * The only remedy is to replace the bearings.
• A large motor is made with feeler gauge. The air space between the rotor and the stator must be the same at all points
for not replaces bearing.

Overload:
@ Check: * Remove the load or belt.
• Turn on the shaft by hand usually a broken past or dirty mechanism will prevent the shaft from moving freely.
• To connect the ammeter in series with each live wire ( snap-around-voltmeter and ohmmeter to test ). The current in
the nameplate is same as the reading. Excessive reading is one phase short.
• To test voltage, resistance and current.

Open Phase
@ Cause: * Motor will continue to run but have less power.
• Broken wire in-group of coil or a loose connection.

@ Remedy : * Locate the open coil.

• Rewinding the open coil or if it is possible, connect the open point.
• The motor will continue to run if phase open, but will not start if at standstill, conditions are similar to those of a blown
fuse.

Shorted coil or Group

@ Cause : * Noisy operation.
• Smoke.
• When insulating enamel on the wire fails, individual turn become shorted and coil extremely hot and burn out.

@ Check: * Locating defective coils by means of the eye or balance test.

• By means of the growler.
@ Remedy: * Cut the entire coil at one point at the back and twist the turn on both sides. Be certain the turns are free
of insulation before wire twist.
• If an entire group is burn out the motor should be rewound.
Loose Rotor Bars
@Cause: * Produce noisy operation.
• Spark may be seen between the bars and end rings while the motor is running.
• The motor may not rotate.
@Check: * Glower and hacksaw use to test.
@Remedy: * Resoldering or welding.
@Notice: * Not use above procedures for a die cast aluminum winding.

Wrong Internal Connections

@Check: * Remove motor.
• Place large ball bearing in the stator.
• Switch is closed to supply current to the winding.
• If connection wrong, the ball bearing will remain stationary.
@Remedy: * For medium and large sized motors should be used reduced voltage or a fuse may
blow.
• Reconnect the connection as data of coil.

Frozen Bearing
@Cause: * Oil or Lubrication oil is not supplied or not sufficient.
• Expansion the bearing by heat and may weld to the shaft.
• Impossible to rotate.
@Remedy: * The shaft has to be turned down on a lathe to the new size and new bearing made.
• If ball bearing are used replace with new ones.

Defective Controller
@Cause: * The contacts on the controller do not make good contact.
• The motor will fail to start.

Grounded Windings
@Cause: * When motor is touched, it will produce shock.
• Grounds are more than one place, it is equal to short circuit and fuse will blow.
@Check: * Use by test lamp.
@Remedy: * Repair by rewinding.
• Replacing the defective coil.

Reverse Phase
@Cause: * To run more slowly than rated speed.
• Produce an electrical hum indicative of wrong connection.
@Remedy: * Check the connections and reconnect them according to plan.

Open Parallel Connection

@Cause: * A noisy hum.
• It will prevent the motor from pulling to full load.
@Remedy: * Check for complete parallel circuit.

AC MOTOR CONTROLLER
Sr.No. Trouble Possible Cause
1. Motor doesn't start when the 1.1.Open OL heater coil or poor connection.
main contact close. 1.2.Main contacts not making.
1.2.1. One or contacts wear sufficiently.
 1.2.2. Dirty.
1.2.3. Gritty.
1.2.4. Burned.
1.3. Broken, Loose or dirty terminals connection.
1.4. Dirty or broken pigtail connection.
1.5. Open resistance unit or open autotransformer.
1.6. Obstruction on the magnet core, preventing the contacts from closing.
1.7. Mechanical trouble, mechanical interlocks, gummy pivots, poor spring tension s
on.
2. If the contact does not closed 2.1. Open holding coil ( Test by test lamp )
when the start button is 2.2. Dirty start button contacts or poor contact
pressed. 2.3. Open or dirty stop button contacts ( More than one station, check each station.
For forward-reverse station, interlocked, check all contacts )
2.4. Loose or open terminal connection.
2.5. Open OL relay contacts.
2.6. Low voltage.
2.7. Shorted coil.
2.8. Mechanical trouble.

3. The contacts open when start 3.1. Maintaining contacts that don't close completely or are dirty, pitted, or loosed.
button is released. 3.2. Wrong connection of station to the controller.
4. Fuse blow when start button is 4.1. Grounded contacts.
pressed. 4.2. Shorted coil.
4.3. Shorted contact.
5. The magnet coil is noisy in 5.1. Broken shaded pole causing chattering.
operation. 5.2. Dirty core face.
6. Magnet coil is burned or 6.1. Overvoltage.
shorted. 6.2. Excessive current due to a large magnetic gap caused by dirt, grit or mechanical
trouble.
6.3. Too frequent operation.

Testing
• Opens • Shorted resistance
• Shorts • Low voltage
• Grounds • High voltage
• Continuity • Excessive amperes.
• Shorted coils • Broken connection
• Open coils • Dirty connection
• Grounded coils • Loose connection
• Open resistance • Many other mal-functioning component may be tested with comparativ
case

Lightning Calculation
1. There are 2 types in lightning cable, Cu and Aluminum.
2. When roof is metal sheet , It should use Aluminum cable .
3. Lightning tape standard size is 25mm width x 3mm thickness.
4. Earthing should be normal earthing system, then standard amount of resistance is Re < 10Ω
5.

BI (Junction)

Earth Spike or Earth Plate Cu.

6. Standard Lightning final is a 300mm or 600mm long Cu final etc.

Allowable Cable Bending

R < 6D Where R is Bending Radius
D is Diameter of the cable( outer )

Conduit Size Calculation.

Space factor : - The ratio of the total CSA of cables to the CSA of the conduit housing;
it is expressed as a percentage . The stated maximum value for conduits is 40%.

CSA Cables
Space factor =
CSA Conduit

e.g. What size of conduit is required for 4x2.5mm2 & 4x6mm2 PVC cables.

100 x CSA cables

CSA Conduit = mm2
40
= 100/40(4x0.7854 x3.52 + 4x0.7854x4.92)
0.7854 Conduit Diameter = 10 x 0.7854 ( 3.52 + 4.92 )
Conduit Diameter = √362.6 = 19.1 ≈ 20mm

IEE Table B.5M

Nominal Number & Diameter Nominal
Conductor of wire (No/mm) Overall
Size (mm2) Diameter (mm)
1.0 1/1.13 2.9
1.5 1/1.38 3.1
2.5 1/1.78 3.5
2.5 7/0.67 3.8
4 7/0.85 4.3
6 7/1.04 4.9

Power Distribution
IEE Definition Range of voltage
1. Extra Low Voltage (ELV)
0-50 VAC or 0-120VDC between conductor to earth.
2. Low Voltage (LV)
above ELV to 1KV AC(1500Vdc) between conductors or 600V AC (900Vdc) between
conductors & earth.
3. Extra high pressure : above 3KV
4. Variation : ± 6% for voltage.
± 1% for frequency.

Think Effect for design the substation

1. Electrical Single Line Diagram.
2. Floor Area ( standard BS area is 20m2for every one transformer)
3. Height (lift enough height is 2.75m)
4. Roof
5. Doors ( normally it is heavy aluminum louver door or heavy duty aluminum door)
6. Ventilation ( artificial heating & moisture during winter )
7. Natural light ( desire ) & some form of light ( secondary )
8. Fire Risk
8.1 Ignition oil in transformer and CB
8.2 Transformer short circuit in winding.
8.3 Oil vaporize and lose connection => expansion.
8.4 CO2 fire extinguisher use.
9. Package substation ( dry type transformer and ACB up to 1600A to avoid oil explosion )
10. To lay cable trench 0.76m depth & 0.76m wide, covered with heavy duty MS plate or Steel plate ).
Busbar Size
Busbar Size Ampere Busbar Size Ampere
1/8 x 1 (inch) 125 1/4 x3/4 (inch) 187
3.2 x 25.4 (mm) 6.4 x 19 (mm)
1/8 x 1-1/2 (inch) 187 1/4 x 1 (inch) 250
3.2 x 38 (mm) 6.4 x 25.4 (mm)
1/8 x 2 (inch) 250 1/4 x 1-1/4 (inch) 315
3.2 x 51 (mm) 6.4 x 32 (mm)

3/16 x 1 (inch) 187 1/4 x 1-1/2 (inch) 375

4.8 x 25.4 (mm) 6.4 x 38 (mm)
3/16 x 1-1/2 (inch) 281 1/4 x 1-3/4 (inch) 437
4.8 x 38 (mm) 6.4 x 45 (mm)
3/16 x 2 (inch) 374 1/4 x 2 (inch) 500
4.8 x 57 (mm) 6.4 x 51 (mm)
1/8 x 5/8 (inch) 78 1/4 x 2-1/4 (inch) 562
3.2 x 16 (mm) 6.4 x 57 (mm)
1/8 x 3/4 (inch) 100 1/4 x 2-1/2 (inch) 625
3.2 x 20 (mm) 6.4 x 63.5 (mm)
3/8 x 1 (inch) 375 1/4 x 3 (inch) 750
9.5 x 25.4 (mm) 6.4 x 76 (mm)
3/8 x 1-1/4 (inch) 470 1/4 x 4 (inch) 1000
9.5 x 32 (mm) 6.4 x 102 (mm)

3/8 x 1-1/2 (inch) 560 1/2 x 1 (inch) 500

9.5 x 38 (mm) 12.5 x 25.4 (mm)

3/8 x 1-3/4 (inch) 655 1/2 x 1-1/4 (inch) 625

9.5 x 45 (mm) 12.5 x 32 (mm)
3/8 x 2 (inch) 750 1/2 x 1-1/2 (inch) 750
9.5 x 51 (mm) 12.5 x 38 (mm)
3/8 x 2-1/4 (inch) 840 1/2 x 1-3/4 (inch) 875
9.5 x 57 (mm) 12.5 x 45 (mm)
3/8 x 2-1/2 (inch) 935 1/2 x 2 (inch) 1000
9.5 x 63.5 (mm) 12.5 x 51 (mm)
3/8 x 3 (inch) 1120 1/2 x 2-1/2 (inch) 1250
9.5 x 76 (mm) 12.5 x 63.5 (mm)
3/8 x 4 (inch) 1500 1/2 x 3 (inch) 1500
9.5 x 102 (mm) 12.5 x 76 (mm)
2 x 9.525 x 101.6 3000 1/2 x 4 (inch) 1995
12.5 x 102 (mm)

Note: Conversion ratio 1/8 = 15.625

1mm2 = 1.55

Symptoms
1. Battery does not hold
charge
2. Specific gravity
constantly low
3. Light dim
4. Voltage 1.8 or less per
cell on headlight discharge
5. Two adjacent cells
"dead" or reversed polarity.
6. Low electrolyte level in
one cell
7. Frequent topping up
necessary.
8. Bulged container cell
covers lifted
9. Very hot & smelly
Battery (Vehicle)
Faults
1.1 Excessive demands on battery.
1.2 Current leaking away
externally.
2.1. Battery discharging back by
generator.
2.2. Local action in cells
3.1. Internal short circuit in one or
more cells
3.2. Insufficient charging
4.1. Defective cell
4.2. Electrolyte lost
5.1. Short between adjacent cells.
6.1. Electrolyte leaking
7.1. Battery being overcharge
8.1. Buckled plates
8.2. Fractured plate grids
9.1. Acid weakness
Causes
1.1 Overloading of electrical system
1.2 Stop light staying on wiring
faults
2.1. Generator cut out opening.
2.2. Impurities in electrolyte.
3.1. Worn out separators buckled
plates, Sediment shorting bottom of
plates
3.2. Generator or regulator faulty
abnormal running conditions
4.1. Internal short between plates
4.2. Cracked casing
5.1. Cracked cell partition.
6.1. Cracked container.
7.1. Regulator faulty voltage setting
too high.
8.1. Neglected maintenance
8.2. Worn-out battery prolonged
under charging.
9.1. Check battery acid level &
intensity
9.2. Fill up acid in every 1-1/2
month or granted time.
 Illumination
&
Lighting
Light Source
(a) Sun & Reflection from sunshine
(b) Friction with materials
(c ) Nuclear fusion
(d) Coal, wood, gasoline etc. burning

Illumination Theory
Luminious Flux φ : Total emission of light within 1sec.
unit : 1 lumen = 1/60 watt .or. 0.00147 watt
Luminious Intensity I : I = φ/w where w= 4π radian
unit : candela (cd) .or. candle power ( cp)
Standard Candle : make by pure wax (ysm;za,mif;ppfppf)
7/8 in diameter
120 grains .or. 7.776 gm burning within 1 hr. time
Illumination ( E ) .or. ( P )
E = φ/A where φ = Flux in lumen on surface area.
A = Working surface
unit : lumen /ft2 => F.C .or. lumen/m2 => Lx (Lux) where 1 lux=0.093 F.C
Inverse Square Law Light Source

E ∝ I / r2 r

Working Surface

Lambert Cosine Law

E = I Cos3 θ / d2

Utilization Factor .or. Utilization (Coefficient of Utilization )

It is ratio of flux(φ0) which is flux emission by light source, and flux φw direct down on the working plane.
η = φw / φ0
Utilization is very important factor in Illumination & Lighting design.
It needs to find out in table that color of room, maintenance factor, and light typical distribution .or. effective light percentage
Lighting .or. Illumination System
It can use indoor .or. outdoor
1. Direct System.
2. Semi Direct System
3. Semi - Indirect System.
4. Indirect System.
Table 39-3 from Gray & Wallace
Classification Approximate distribution of light output of
luminaries percent
Upward Downward
Direct 0 - 10 100 - 90
Semi Direct 10 - 40 90 - 60
Direct- Indirect ( General diffuse ) 40 - 60 60 - 40
Semi-indirect 60 - 90 40 - 10
Indirect 90 - 100 10 - 0

In G.T.I Course as British Standard

1. Direct - 90% downward
2. Semidirect  45% downward, 30% upward & the rest drop on wall.
3. General Diffuse  40% downward, 40% upward & the rest drop on wall.
4. Semi Indirect  10% downward, 75% upward the rest drop on wall.
5. Indirect  80% , 90% upward & the rest distribute on floor & wall.

In R.I.T Course as SI unit

1. Direct  75% downward
2. Semi direct  45% downward
3. Direct & Indirect (General diffuse)  30% downward
4. Semi Indirect  25% downward
5. Indirect  20% downward

Maintenance Factor
Maintenance factor depends upon cleaning condition of lighting fixture.
This clearance depends upon amount of soiling(dust).
I. Slight soiling .or. soiling rate low  shops, office & schools.
II. Normal soiling  all other factories.
III. Heavy soiling .or. soiling rate high  blast, furnace factories, smith, mine & some department of textile factories.

A. Cleaning of lamps & fitting every year (end of year)

B. Cleaning of lamps & fitting every 2 years
C. Cleaning of lamps & fitting every 3 years

It is point number .or. rational number only.

Maintenance factor inverse to D.F ( Depreciation Factor )
Depreciation factor is full number.

Illumination Designing Steps ( Referred to R.I.T. 4th Year Course )

Step.1.. Find out the Room index k = (2l + 8w ) / 10h
Step.2.. Ceiling Reflection factor rc & walls reflection factor rw fixed and then find out η from table.
Step.3.. Find (lux) of TL rom table for φlamp & φfit &
Step.4.. Find required illumination which effect to working plane by table ( E in lux )
Step.5.. Find out numbers of fitting by
E x S x d.f ExS
Nfit = -------------- = --------------------
φfit x η φfit x η x m.f
where d.f - depreciation factor from cleaning type & soiling rate.
1
m.f = --------- = maintenance factor
d.f.

Step.6.. Counter check - Find out φ0 &

φ0 = Nfit x φlamp x Nos of lamp / fit
φ0
Ew = ------------- Where S = Area in meter2
S x d.f. φ0 =Normal Luminaries flux
Compare Ew & E of selected from table, if it is almost same Nfit can be accepted.
Step.7.. Arrange lamp fitting in Room

# 1 lumen = 1/680 watts or 0.0147 watt

# I - luminous intensity in c.d. ( candela ) I = φ / w where w is solid angle
# Lambert Cosine law - E = I/d2 x Cos θ
# Slight soiling - shops, office, school, etc.
Normal soiling - All others factories
Heavy soiling - Blast, furnace for dairies, smith, mines & textile Factories.
# Reflection factor ( absorption factor rc & rw )
a. White or very light color - 70%
b. Light color - 50%
c. Medium shades - 30%
d. Dark color - 10%
# Twice of distance apart from wall & nearest fitting is equal to distance between fitting by fitting.
# 1 lux = 0.093 F.C. ( foot-candle )
# Working plane & E (F.C) ( 1-lux)

1. Drawing office - 50~100(75) F.C or 537.6~1075.3(806.4) lux

2. General office(Precision) - 50(30) F.C or 537.6 (322.58) lux
3. General office( Normal ) - 50 F.C or 537.6 lux
4. Book keeping/ Accountant / Typist - 50~100(75) F.C or 537.6~ 1075.3(806.4) lux
5. Desk / Reading / Writing - 50 F.C or 537.6 lux
6. Corridor & Stair - 2~10 F.C or 21.5~107.5 lux
7. Hotel / Hospital & Stair - 5~10 F.C or 53.76~107.5 lux
8. Classroom - 30~50 F.C or 322.5~537.6 lux
9. Sewing (light color) - 50 F.Cor 537.6 lux
10. Sewing (Deep color ) - 200 F.C or 2150.5 lux
11. Manufacturing Factory(Base) - 30 F.Cor 322.6 lux
12. Manufacturing Factory(Normal)-50 F.Cor 537.6 lux
13. Manufacturing Factory(Precision) - 100~200 (150) F.C or 1075~ 2150 (1612.9)lux
14. Hospital Operation table - 300 F.C or 3225.8 lux

# Hospital
1. Ward & private room - 3 F.C or 32.26 lux
2. Waiting & receiving room - 7 F.C or 75.27 lux
3. Operating table - 300 F.C or 3225.8 lux
4. Operating room - 30 F.Cor 322.58 lux
5. Laboratories - 20 F.Cor 215.05 lux

# Industries
1. Assembling shop ( Rough work ) - 7 F.C or 75.27 lux
2. Assembling shop ( Ordinary work ) - 10 F.C or 107.5 lux
3. Assembling shop ( Medium work ) - 20 F.C or 215 lux
4. Assembling shop ( Small m/cs ) - 50 F.C or 537.6 lux
5. Assembling shop ( very small works) - 100 F.C or 1075.2 lux

# Glass work
1. Mix & Furnace room - 5 F.C or 53.7 lux
2. Glass Blowing m/c, Grinding, cutting / Glass to size, Silvering, Pressing - 10 F.C or 107.53 lux
3. Fine, Grinding, Beveling, Inspection, Etching & decorating - 20 F.C or 215 lux
4. Glass cutting, Fine inspection - 50 F.C or 537.6 lux

# Hotel
1. Lounge & Dining Room - 7 F.C or 75.27 lux
2. Writing Room - 7 F.C or 75.27 lux
3. General - 7 F.C or 75.27 lux
4. Tables / Kitchen - 7 F.C or 75.27 lux
5. Bedroom - 5 F.C or 53.76 lux

# Office & Bank

1. General office works - 20 F.C or 215 lux
2. Private Office - 15 F.C or 161.3 lux
3. Typing & Bookkeeping - 20 F.C or 215 lux
4. Filing - 20 F.C or 215 lux

# Chemical works
1. Hard Furnace, Boiling Tanks, Stationary dries, Stationary or Gravity Crystallizing, Mechanical
Furnace, Generators & Still, Mech. Dryers, Evaporator, Filtration, Mech. Crystallizing, Bleaching- 7 F.C or 75.27 lux
2. Tanks for cooking, Extractors, Percolators, Nitrators, Electrolytic Cells - 10 F.C or 107.52 lux
# School
1. Day Classroom - 15 F.C or 161.29 lux
2. Drawing & Art - 20 F.C or 215 lux
3. Gymnasiums - 10 F.C or 107.52 lux
4. Laboratories - 15 F.C or 161.29 lux
5. Lecture / Theatre - 10 F.C or 107.52 lux
6. Manual Training - xxxxxxxxxxxxxxxxxxxxx
7. Sewing - 20 F.C or 215 lux
# Machine Shop & Fitting Shop
1. Ordinary bench & m/c work - 10 F.C or 107.52 lux
2. Rough bench & m/c work - 10 F.C or 107.52 lux
3. Medium bench & m/c work, ordinary automatic m/c, rough grinding m/c, Fine Buffing & Polishing - 20 F.C or 215 lux
4. Very Fine Bench & m/c works, Grinding (fine) - 100 F.C or 1075.2 lux
 FLUORESCENT
LAMPS ( S.E.E.)
Lamp Type Watt Nominal
luminous flux Standard Fluorescent Lamp in Market
after 100 hrs
of burning in
Lux
White Warmwhite Daylight Warmwhite White
33 29 55
deluxe 32 deluxe 34
"TL" 4W 100
6W 230
8W 370
13W 710
20W 1080 1080 820 750 750
25W 1650 1650 1250 1130 1130
40W 2800 2800 2120 1880 2000
65W 4400 4400 3300 3000 3200
"TL" D 15W 550 580
30W 1350 1300
"TL" E 22W 750
32W 1600 1700 1220 1300
"TL" EM 40W 2250 2380 1660 1800
"TL" F 40W 2460
65W 4000
"TL" M 40W 2650 2650 1780 1900
65W 4400 4400 3000 3100
125W 7300
"TL" MF 40W 2460
65W 4000
"TL" S 20W 900 900 620
40W 2300 2300

Table of Color comparison between hot cathode florescent tubes

Kelvin American / Japanese English Australian
approx. (e.g. Sylvania) (e.g. Thorn-Atlas) (e.g. Phillips, Osram,
Mazda, Crompton)
2800 Warm white Warm white -
2900 - - Warm white
3000 Warm white deluxe Warm white deluxe Warm white deluxe
3200 Natural deluxe Natural deluxe -
3500 White White White 3500K
3800 Natural white - White deluxe
4150 - - Kolor-rite
4200 - Natural -
4300 Cool white Daylight White
6500 Daylight Tropical daylight Daylight

Comparison of light sources ( Following figures are an approximate general guide only)
Efficacy Approx. Lamp Relative
Source (l/W) life hrs source cost
Incandescent 14 1000 60W Low
Coiled coil
Tubular fluorescent 65 7500 40W Medium
White
Mercury vapor (clear) 45 8000 250W Medium
Mercury vapor color-corrected 50 8000 250W Medium
MV Metal halide 75 8000 400W High
LP sodium 130 6000 100W High
HP sodium 95 8000 400W High
Tungsten halogen 28 2000 1000W Low
 TROUBLESHOOTING FOR COMMON FAULTS IN LUMINAIRES
( Adapted from table supplied by GTE Australia )
Problem System Possible Case Corrective maintenance
Lamp fail to All Blown fuse or Replace or reset as necessary. Look for possibles short-circuit in wiring or
light open circuit -
breaker
Pre - heat Reset type starter Reset manual type. If automatic type, extinguish circuit or remove starter
not reset. approximately one minute, then re-energize circuit. If starter cuts out agai
further. ( See other possible case in this section. )
All Wrong lamps Check ballast label, replace with correct lamp. Whenever practical, it is ad
the power off before making a replacement.
All Poor contact • Adjust lamp to seat it properly. Some two-pin lamps have two pits or
between lamp and , which are aligned at right angle s to a line between the pins.
lampholder • A checks of the position of the pips will indicate whether or not the la
rotated into the socket correctly. In the conventional tombstone type o
or mark should line up with the center of the socket opening.
• Gently twist lamps with recessed double contactor bases to assure pro
• Thoroughly clean dirty sockets.
• If sockets are loose, adjust or replace them.
• Replace sockets which are corroded, broken, or show evidence of arci
• Check spacing and alignment of lampholder. If they are too far apart,
poor contact.
• Adjust them or replace the fixture.
Quick start . Lack of proper In a rapid start or quick start system, a lamp which has one or two blacke
Rapid start. cathode heat. be receiving adequate cathode heating. This may be caused by poor conta
problems within the ballast, by use of ballast which do not deliver minim
requirements, by improper wiring or low-line voltage . Each of these is d
following pages.
Various devices are available to test cathode heater voltage. Among these
mounted in lamp bases. These are go/no-go types of indicators which show
presence or absences of cathode heat, but which give no indication of qua
reason , they will not necessarily reveal insufficient heat. It is better to use
voltmeter with a lamp base attachment containing a resistor for a " dumm
the proper cathode current. With this type of indicator. cathode, heater vo
obtained from lamp manufacturers. They are also indicated on most tester
The insertion of a tester into a dirty or corroded socket often scrapes the c
enough to obtain a proper reading. Make sure that the contacts are in goo
that the lamp was sealed as well as the tester. If the tester shows improper
investigate further.
All Normal end of life Cathode coating is exhausted .
of lamps. This is characterized by dense end blackening, extending from the end of
the lamp wall for 5-8 cm . Lamps may flash for a short period of time or a
shimmer. Instant start lamps may swirl.
The ends of pre-heat lamp may flash on and off. If an arc strikes, it may b
by a shimmering effect during the short time it exists.
In some two-lamp circuits, particularly series sequence instant start and ra
circuits, a good lamp may burn at reduced brightness, in a glow state, pos
the cathodes. Also both lamps may be out when only one has failed. Chec
individually. Replace failed lamps promptly to avoid ballast damage cause
and overheating. If a good lamp is known to have burn at low brightness f
show indications of being near the end of life, it should also be replaced, s
have been significantly reduced because of cathode damage. With any typ
simplest procedure is usually to test lamps in an adjacent fixture which is
operating properly and then replace as necessary.
Pre-heat Welded starter This is usually indicated bay a lamp glowing at the ends, but not attempti
contacts or starter in an adjacent fixture known to be operating properly and replace i
shorted starter ends of the lamp have been glowing and it starts immediately upon remov
capacitor replace the starter.
Pre-heat Starter at end of Check the starter in an adjacent fixture known to be operating properly, o
life with one of the following: A new starter, a starter from a fixture operating
dummy starter can be made from an old starter simply by shorting the pin
 inserted into the starter socket and removed when the lamp ends begin to
should be repeated three or four times if necessary. If the lamp has not be
does start on any one of these attempts, the troubles is in the previous star
A manual starter can be made by connecting a hand switch with 300mm o
series with the two posts in a starter base . It is used in the same manner
starter except that the switch is opened rather than the base being remove
Lamp fail to All Ballast not All ballasts must satisfactorily limit the flow of current in the lamp to a va
light delivering within reasonable limits of the lamp rating. In addition, pre-heat ballasts
minimum lamp sufficient pre-heat current and starting voltage; instant start ballast must p
requirements starting voltage and starting current; quick start and rapid start ballast m
sufficient voltage between lamp terminals, from lamp terminal to starting
currents for cathode heat. These values may be obtained from lamp suppl
To check, use suitable ammeters and voltmeters as directed in AS specific
ballast manufacturer's publications. Some simple tests can be made with
following the ballast manufacturer's recommendations.
Replace ballast. It is highly recommended that approved ballasts be used
possible.
Instant start High humidity or Remove , clean and replace the lamps, Use a mild soap solution rather tha
Trigger start accumulation of which can remove the lamp's silicone coating. If it is advertently removed
Rapid start dirt on lamps be wiped with a silicone cloth. It is advisable to let lamps air dry since wi
cloth may create static electricity which will attract dust.
If humid and dusty conditions prevail, it is advisable to enclose the lamps
All Extreme ambient Correct ambient, if particle. Otherwise, change to a ballast rated for exist
temperatures In conditions of extreme cold, although the lamps do light, their output m
(either hot or they appear to be unlighted.
cold)
All Voltage at fixture Measure with a suitable voltmeter. Correct, or change to a ballast rated fo
too low
Quick start . Inadequate Rapid start and quick start systems require metal starting aids in close pro
Rapid start starting aid lamp and running the length of the lamp. This metal must be at earth pot
the fixture reflector serves as the starting aid.
Provide suitable starting aid. Requirement can be obtained from the lamp
All Improper wiring Examine the wiring to see that it is in accordance with the diagrams on th
Ensure that active, neutral and earthing conductors are correctly connecte
connections to see they are secure. Occasionally, fixtures using the newer
are found with loose leads - leads which were not properly pushed into the
which are used for wire connections instead of lugs and screws. Leads wit
insulation removed has also been found. In some cases, one slot is used fo
although there are two spring clips inside the socket, both wires go under
result in a loose connection for one of them.
Check the socket arrangement. In some sockets wires from adjacent holes
be connected to opposite pins while in others they are connected in paralle
Make sure there are no short circuit such caused by leads contacting the fi
There should be nearly full line voltage between the active lead and the m
Measure voltage across the lamp from the lamp holder on one end to the l
other ( where only one connection at each end is live being sure to measur
ones). Use a voltmeter which has an input impedance of 100 ohms per vo
there is no voltage or extremely low voltage, measure at succeeding point
power line to determine the location of the problem.
In some installations, particularly those using instant starts lamps which r
circuit voltages, an interlocking type of socket is used for safety . With th
the primary ballast circuit is not completed unless a lamp is inserted in th
obtain readings of ballast output it is necessary to complete this circuit.
In a pre-heat system, with dummy starter installed, both ends of one lamp
not, or if in three or four attempts there is no effort to start when the dumm
there could be an open circuit.
If one end of each lamp glows, the wiring is crossed.
In each case, check the wiring and correct it in accordance with ballast la
All Leak in lamp Indicated by absence of fluorescent glow when lamp is exposed to a spark
lamp.
Pre-heat, Open circuit in Improper earthing, improper wiring, broken lampholder, or insufficient b
Quick start lamp electrodes which can cause excessively high voltage to be impressed across the catho
Rapid start this. Other causes are transportation damage, poor weld, broken coils and
leaks.
 Test with continuity tester or by connecting adjacent lamp contacts in seri
resistance such as a 25-watt incandescent lamp on a 240V line .
Another method of inspecting the cathode is to use a simple shadowgraph
readily constructed by making a small hole in a square of cardboard or oth
material that is held in front of shielded filament lamp. The lamp to be ex
against the pinhole and a shadow of the cathode will be projected on the s
opposite the cardboard. By tuning the lamp slowly, the cathode, leads, etc
examined and any breaks, distortions, or missing cathodes will be easy to
lamp.
All Short circuit If one lamp is out and the other is operating at full brightness in a rapid s
within ballast sequence circuit, there is probably a shorted starting capacitor. This can b
checking continuity between the leads to the lamp that is out. If any tow l
ends show continuity, there is a short circuit. Replace the ballast.
All Ballast end of life when the insulation on the ballast windings fails, the ballast will no longe
requirements and has , therefore , reached the end of its life. Time and te
the life of the insulation. If the ballast is subject to high operating temper
temperatures over 90 deg C, its life will be substantially reduced. Genera
that each increase of 10 deg C above 90 deg C rating will halve ballast lif
Leaking compound , expect for a small amount at the lead holes, which is
or brittle insulation; and discoloration on the metal case are all indication
approaching or having reached end of life. The simple fact that a ballast s
a true indication that the ballast is functioning properly. Often many succ
appear t have short life in a given fixture before it is realized that the balla
the end of useful life.
Check with appropriate continuity testers, ammeters and voltmeters as de
manufacturers' publications. Replace the ballast.
Slow of erratic All Wrong lamp See appropriate section in "Lamps fail to light"
starting
All Poor contact See appropriate section in "Lamps fail to light"
between lamp and
lampholder
Quick start Lack of proper See appropriate section in "Lamps fail to light"
Rapid start cathode heat
Pre-heat Sluggish starter, Test starter in adjacent fixture known to be operating properly. Replace st
causing prolonged
flashing at each
start
All Ballast not See appropriate section in "Lamps fail to light"
delivering
minimum lamp
requirements
All High humidity or See appropriate section in "Lamps fail to light"
accumulation of
dirt on lamp
All Extreme ambient See appropriate section in "Lamps fail to light"
temperatures
(either hot or
cold)
All Voltage at Measure with suitable voltmeter. If fluctuating voltage is suspected, a reco
luminaries low or will be helpful. Correct supply.
fluctuating
Quick start Inadequate See appropriate section in "Lamps fail to light"
Rapid start starting aid
All Improper wiring See appropriate section in "Lamps fail to light"
New lamps fail All Wrong lamps See appropriate section in "Lamps fail to light"
within the first
few days of
operation
All Wrong ballast Verify that proper ballast is used for the fixture and for existing electrical
environmental conditions. Ballast must be a.c. or d.c., depending on supp
and must be of correct line voltage and frequency rating . If low temperatu
exist, a low temperature ballast should be used. Replace with appropriate
Pre-heat reset-type starter See appropriate section in "Lamps fail to light"
 not reset
All Improper wiring See appropriate section in "Lamps fail to light"
All Leak in lamp: See appropriate section in "Lamps fail to light"
may develop so
slowly that lamp
will operate
satisfactory for a
short period of
time
Pre-heat Open circuit in See appropriate section in "Lamps fail to light"
Quick start lamp electrodes
Rapid start
All Short circuit See appropriate section in " Lamps fail to light" short circuit can occur wh
within ballast to operate at excessive current. To check , follow ballast manufacturers' s
procedures.
As a general rule, the following can be done: however, there are some exc
Place an ammeter in series with the lamp and if the meter reads more tha
rated lamp current, replace the ballast. For pre-heat and instant start syste
ammeter in series with the lamp, preferably between the lamp and the bal
lead which is at earth potential. For quick start and rapid start systems do
however, after the lamp is ignited remove the adjacent secondary lead to a
cathode heating current in the reading.
Short lamp life All Wrong lamps Although some lamps may operate for a period of time on the wrong type
will nearly always be serious disadvantages to such operation. For examp
milliampere (high-output) lamps will operate on 1500 milliampere ballast
substantial sacrifice in lamp and ballast life, lamp maintenance and efficie
Operating 1500 milliamperes(VHO) lamps on 800 milliampere ballast ca
effects reducing ballasts and possibly lamp life and efficiency.
All Normal failures Although rated life is usually many thousand hours, it is by definition the
which 50 percent of the lamps in a statistically large sample have failed. A
lamp will fail before this time and some after . One must expect a small p
comparatively early failures.
All Short burning Rated life of fluorescent lamps is based on an average burning period of th
cycle start. If the burning period per start is lengthened, the life of the lamp wil
the other hand, if the average burning periods decreased, lamp life will be
the operating schedule and the local economics. It is often found that turn
for the short period of time, to reduce the electrical consumption, actually
increase in installation operating costs because of the adverse effects on la
All Poor contact See appropriate section in "Lamps fail to light"
between lamp and
lampholder
Quick start Lack of proper See appropriate section in "Lamps fail to light"
Rapid start cathode heat
All Ballast not See appropriate section in "Lamps fail to light"
delivering
minimum lamp
requirements
All Voltage at fixture If the voltage delivered to a pre-heat to rapid start fluorescent luminaries
too high to too normal , light output will increase, but the lamp will frequently instant sta
low without proper cathode preconditioning, causing rapid deterioration of the
resulting in reduced lamp life. Occasionally with preheat circuits, this ins
be recognized. The lamps will start without preheating or will sometimes
then start normally, that is preheating the cathode and then striking the ar
its effects on the lamps, a high line voltage can cause the ballast to run at
high currents, thereby reducing its life. The high current will also decrea
maintained light output.
If the voltage at the luminary is low, light output will be reduced, lamp o
unstable, and starting can become slower, more strained or prolonged, w
to the cathodes and decreases lamp life.
In either case check line voltage at the luminaries with a standard voltme
voltmeter if fluctuating is suspected. Correctly supply as necessary or us
designed for the specific voltage being supplied. Consult ballast manufac
recommended practical limits.
 All Wrong ballast See appropriate section in "New lamps fail to light within the first few da
Pre-heat Wrong starter Consult starter manufacturers' publication or package and replace with co
manual or automatic reset type is advisable for installations where a failed
replaced within one hour.
Pre-heat Sluggish starter See appropriate section in "Slow or erratic starting"
Pre-heat Premature The lead lamp in a two-lamp circuit is often prone to start before its catho
starting preheated. Since this characteristic cannot often be visually recognized, w
lamps have shorter life than the lag, it is advisable to use a starter designe
effect.
Series Lamp operating When one lamp in a two -lamp series sequence circuit has failed, the othe
sequence in the glow state reduced brightness, in a glow state. This may damage the cathode of the
reduce its life. Replace failed lamps promptly. If a lamp that has burned
exhibits signs of being near the end of life (see "Normal end of life of lam
idea to replace it at the same time the failed lamp is being replaced.
All Improper wiring See appropriate section in "Lamps fail to light"
All Open circuit in See appropriate section in "Lamps fail to light"
lamp electrodes
All Short circuit See appropriate section in "Lamps fail to light"
within ballast
Snaking All Impurities At the arc in a fluorescent lamp may swirl and twist within the lamp. Thi
blinking or in a new lamp and will disappear when the lamp has been operated a few
flickering and off a few times one half hour or more apart. Occasionally, this "sneak
in a lamp during normal operation. Turning the lamp off and on usually
not, replace the lamp. If other lamps in the same luminaries also swirl, in
All Normal Although this is not often a problem with the holding properties of today's
stroboscopic effect can be reduced by using the warm colors, which have the slowest rate of d
due to alternating operating on lead-lag circuit or by operating on three-phase power supplie
current
All Poor contact See appropriate section in "Lamps fail to light"
between lamp and
lampholder
All Normal end of life See appropriate section in "Lamps fail to light"
of lamps
All Low lamp wall Low lamp wall temperature caused by draughts from outside air, air-cond
temperature cause flickering or blinking. Protect or enclose the lamp.
All Wrong ballast If the ballast frequency rating is not the same as the line frequency, flicker
Replace with ballast of proper rating.
Pre-heat Wrong starter Remove the starter while the lamp is lighted. If the flashing stops, the sta
size, or is defective. Replace it.
Pre-heat Sluggish starter See appropriate section in "Slow or erratic starting"
Pre-heat Starter not cycling Characterized by rapid blinking of lamp ends. Test starter in adjacent circ
correctly to proper
preheats
electrodes.
All Ballast not See appropriate section in "Lamps fail to light"
delivering
minimum load
requirements
All Voltage at Measure with suitable voltmeter and correct. See appropriate section in "L
luminaries too light"
high or too low
All Improper wiring See appropriate section in "Lamps fail to light"
All Open circuit in See appropriate section in "Lamps fail to light"
lamp electrode

PLC MAINTENANCE, TROUBLESHOOTING

CONSIDERATION OF THE OPERATING ENVIRONMENT
• The PLC installed in an enclosure, NEMA type metal enclosure. NEMA type enclosure must be planned to allow adequate
room for incoming control wires & power wiring and easy access to all parts and wires for installation, future alterations,
and troubleshooting.
• Temperature of operating limit ( upper & lower ), normally 0 degC (32degF) and 60 degC ( 140 degF )
• Moisture, Dust, and Corrosive Atmosphere: - It may operate in High Humidity.
- Level of moisture
- Dust
- Corrosive Atmosphere (Chemical plant, refineries)
where oxidizing fumes may be present, electrical
connection can fail to buildup of oxides on
the wires and terminals.
• Vibration - excessive vibration ( transmitted from nearby vibrating equipment ) can effect to PLC
malfunction . It can be reduced by shock-prevention mountings.

RECEIVING CHECK, TESTING AND ASSEMBLY

• Receiving - When receive the PLC system from manufacturer, inspect the packing boxes for any
Obvious damage.
Checking - If it is damage, take a picture of them before opening
- In case the parts inside the packages may also be damage.
- Check out the inventory that is it same the parts and manual received against the
packing
list provided.
- Review, record & sort out the purchase order and listing of parts which you received
- Many electronic parts and assemblies are easily to damage by small charge of static
electricity, therefore manufacturers normally provide anti-static bags for normal
shipment.
- Before remove that bags, check it out that it's damage and record, return them to
supplier for replacement or recheck. So when it is removed, it may need special
handling like static free environment.
- If the modules are installed into the system, the same precaution is necessary.
- Portable grounding kits are available from some manufacturers to prevent static
damage of parts during handling.
• Testing - After complete assembled, PLC is ready for testing.
- First PLC tested "as is," without attaching any wiring to the I/O modules.
- Electrical jumpers moved around from input to input to check for correct
operation.
* Output program energized indicating light is correct not.
* FORCE mode (use keyboard) may convenient to check for correct input
operation than moving jumpers around as input simulation method.
The disadvantage is that it cannot check to input module operation.
* MONITOR mode can observe the ladder program operation on the PLC
screen, which gives a better view of the PLC internal operation.
- Second, tested with simulator. (Discrete simulator, Analog simulator)
* A switch is attached for each input, and indicating lights attached for each
output
- Third, tested after it is hooked up to the system to operate.
* Direct connects to the PLC with the factory operation system it is to control.
• Disadvantage :- If the PLC is malfunction, the equipment being used for testing can be
damaged. The operator or programmer error can cause sequence problem or
even damage to equipment. Personnel injured during PLC malfunction.
- Above all testing method use in FROCE mode for proper operation by
keyboard (input, output ), this override the system's normal operation through
the input module. FORCE mode could be dangerous to equipment or personnel.
- Testing to peripheral (printers, disk drives and tape drives) also takes special testing
procedure. e.g. a printer can print five different type of information, all five modes of
operation should be tested.
- A complete test of the PLC system and CPU involves checking every function; each input and output
should be checked, for every function (TIMER, COUNTER, MASTER CONTROL RELAY etc.). Even if
it is not to be used initially, check every function for recovery to warranty period.

INSTALLATION, ELECTRICAL CONNECTION, GROUNDING, AND SUPPRESSION

• Initial facts & Battery - Practically all PLCs have backup battery systems. Some system use a
common 1.5V or 9V long life battery or various type of batteries with special
voltage ratings or rechargeable battery that is trickle-charged by a small power
supply in the CPU.
- Separately shipped batteries are installed according to manufacturer's
 instructions.
- Special precaution during installation might include removal of some
modules of wires to prevent static damage or electrical surges to some parts of
CPU.
- In all cases, battery voltage should be checked for compliance to voltage
specifications listed in the PLC manual before installation.
- All PLC systems have at least one fuse; many have a number of different
fuses. These may be in place when the PLC is shipped. If not, the fuses must be
installed according to startup instruction in the manual.
• CPU - Plug in the line cord to CPU & all parts.
- Check the CPU for proper operation as turn the key-switch or master switch from position to
position and check to see that all operating pilot lights come on at the proper time. If it not,
internal visual checks are in order (the faceplate or an appropriate panel may be removed).
Then check for any loose connection.
• Input & Output Modules - Assembly of input and output modules are larger units in the racks
which are not only mechanical supports but also have interconnecting
electrical wires and connections so take care that modules are put
precisely in place.
- Modules are next connected to the CPU with the proper cables, care
must be taken that the connecting ribbon cables are not too twisted or pull during
installation.
- Next, the wires from the external devices and switches are attached to
the I/O terminals. The standard practice of "hand tight" is normally followed.
- Peripheral devices such as printers, disk drives, and tape drives may now be
interconnected to the system by means of their cables.
- Remote station and buses to the other PLCs and computers should not
be connected until the individual PLC checkout is complete.
• Grounding - Proper grounding of wiring of the equipment and cabinet is essential for personnel
safety and assure proper equipment operation.
- Ungrounded or improperly grounded wire or part could become shorted electrically to
metal cabinet or rack, presenting to electrical harzard to users.
- PLC is computer based and computers need a proper and solid grounding system for
consistently trouble-free operation.
• Suppression - Electrical disturbance from devices outside the PLC system can cause program
operation malfunction.
- Electrically inductive nature (Solenoids, starter coils, motors & other devices) cause an electrical pulse to be
back fed and PLC in mistake and PLC sequence flow in malfunction.- Standard copper outer sheath around
shield cable prevent above disturbance.
- Suppressors can absorb above false pulse which passed through external prevention technique and it get no
disturbance signal send to PLC.
- Master control relay system can be provided to override the whole PLC operation to shut down for safety
precaution.

Circuit Protection & Wiring

• Protection
Some major considerations in choosing fuse are
1. Rated current for melting or blow
2. Rated current of PLC
3. Interrupt capability. ( A 20A fuse will not stop 20,000 amps. The current will arc over.)
4. Temperature of the environment in which the fuse will operate. (Higher temperature means faster
action and blowing below rated value.)
5. Type of mounting
6. Replaceable link or one-time operation
7. Time delay or regular-do not use time delay fuses for PLCs; use regular fuses.
8. Other special requirements
9. Consult with fuse specialist
10. Circuit Breaker can reset quickly and do not need to be replaced, but fuse blown faster can give
more protection to PLC
11. Overload protection is accomplished by internal, specially calibrated overload relays in PLC itself
( so it need to reset only)
 12. Wire size must be large enough to prevent line loss, drawn by PLC, it cause voltage drop due to
feeder wire's resistance and PLC can cause erratic PLC operation.
13. It is best to connect PLC and other electronic equipment to separate power feeder lines (to avoid
disturbance).
14. Electronic equipment & PLC can be affected by power wave form distortion, which caused by
following:-
14.1. Surge form lightning hitting power lines
14.2. Disturbances from adjacent building or factories
14.3. Surges from switching action by the power company or in your plant.
14.4. Internal factory power waveform disturbances.
15. Above distortion can correct by line purifier unit, it can not only waveform purify but also
maintain proper stabilization in line voltage. Also it can perform as battery standby unit as UPS.

• Troubleshooting PLC Malfunction

1. Take care safety precaution ( process, power turn on/off, wear glass, insulated handtools, work deliberately, consider the
consequences of each step )
2. Must understanding that what is malfunction? document problem in detail including the date, time, severity and
circumstances of malfunction.
3. Check for replace any blown fuses.
4. Visual inspection.
5. Is power to all control ckt?
6. Are there broken wires?
7. Are switches set in proper position?
8. Have any undocumented alteration to parts been made?
9. Review of terminal wiring diagrams may reveal that an unrecorded change is causing the trouble.
10. Establish that the system malfunction is not caused by an external part or system then check the PLC itself for proper
operation in each applicable mode.
11. Larger PLCs have an available screen readout for CPU status, call up status and refer to operating manual to state it.
12. Any portion not meeting the normal shows an operational area, in some cases just clearing the CPU memory and
reprogramming to eliminate PLC malfunction.
13. If it has another CPU available, replace the one in service with it, and reprogram the old CPU was using. If problem is
corrected, old CPU could be culprit. If it is same problem that it is no problem in CPU and analyzes subparts by substitution
in similar manner.
14. Use MONITOR mode is helpful troubleshooting, by observing the program ladder operation on the screen.
15. FORCE mode is useful in simulating operating conditions. Caution that it is not during actual operation condition.
16. Many PLCs have available a fault indication register display on screen, it may internal fault condition or external fault
condition. Therefore follow up fault register to get correction the problem.
17. PLC malfunctions correct by replace printed circuit board or single electronic component.
18. After replacing finished, it still has problem. Following may happens
18.1. Replacement parts also faulty.
18.2. Another part or parts in the PLC are faulty. Further analysis need.
18.3. Overload cause in the system affect. or severely damage in other portion of
system, so it need to quick pre-check before expansive parts to replace.
( supply voltage must correct )
19. Written log of failures correction for each PLC should be kept. If failure in second time, reviewing the log will enable the
troubleshooter to benefit. The log should include a description of failure and corrective action taken, as well as the date
and shift of occurrence.
20. More spare parts for a particular failure mode may have to keep on hand.

• PLC Maintenance
1. Periodically check the tightness of I/O module terminal screws. They can become loose over a period of time.
2. Periodically check the corrosion of connecting terminals. Moisture and corrosive atmospheres can cause poor electrical
connections. Internally end connectors of PCB also may become corroded.
3. Make sure that components are free of dust. Properly cooling the PLC through a layer of dust is impossible.
4. Stock commonly needed spare parts. Input and output modules are the PLC components that fail most often. Stocking is
especially essential there is no convenient manufacturer's service station and part depot. Maintaining proper levels of spare
parts inventory is a trade-off between costly inventory and prolonged downtime without parts.
5. Keep a duplicate record of operating programs being used. These records should be kept the plant location away from the
PLC operational area. Copies of long expensive programs should be kept off the premises to prevent their loss in case of
fire and theft.
6. Replace the PLC backup batteries more often than their usable life would indicate. The lithium batteries used for backup in
case of lost electrical service are usable for 3-5 years. However, many companies replace them on the yearly on a written
maintenance procedure. The cost of the batteries small price to pay to prevent the loss of lengthily PLC program.
7. Have a written checklist control sheet for each PLC. The sheet should have the dates on which the work is performed and
the dates for the next preventative maintenance due. The next due dates should be entered on a future worksheet listing to
make sure it is done on the date due.
8. Keep a log sheet on maintenance for each PLC in addition to the check-sheet. Records of what, who, and when should be
kept. This log is often combined with the troubleshooting log discussed in the previous section. The combined log sheet
gives a valuable history record and is a guide to buying future PLCs based on performance or nonperformance.
This is typical drawing for Forward Reverse motor control unit in United Cement Project (Singapore). There are 2-type control,
first direct electrical power control by local control selector switch and second automatic PLC computerize control by Siemen
(Germany) technology.
 Typical Control Circuit Diagram
Above typical Drawing is Star Delta starter and automatic PLC computerizes control. unit in United Cement Project
(Singapore).There are 2-type control, first direct electrical power control by local control selector switch and second automatic
PLC computerize control by Simen(Germany) technology.

Above circuit is typical AutoTransformer starter circuit which is useful to control motor starting current by voltage transition,
and which is in two-type first open transition and second close transition.
ILLUMINATION DESIGN TABLE
Incandescent Room Utilization Factor New Conditions Mainte
Lamps Index nance
Factor
Type of fitting v% k rc 0.7 0.5 0.3 Clean Clean Clean
rw 0.5 0.3 0.1 0.5 0.3 0.1 0.5 0.3 0.1 Once once once
Direct 1 0.27 0.21 0.17 0.26 0.21 0.17 0.26 0.21 0.17 Yearly every every
1.2 0.32 0.26 0.21 0.31 0.25 0.21 0.3 0.25 0.21 2 Years 3 Years
1.5 0.38 0.32 0.27 0.37 0.32 0.27 0.36 0.31 0.27
2 0.46 0.4 0.36 0.45 0.4 0.36 0.44 0.39 0.36
0 2.5 0.51 0.46 0.42 0.5 0.46 0.42 0.49 0.45 0.42 Soiling
rate low
| 3 0.55 0.5 0.46 0.54 0.5 0.46 0.53 0.46 0.46
80 4 0.61 0.56 0.53 0.6 0.56 0.53 0.59 0.55 0.53 Soiling
rate
normal
| 5 0.64 0.6 0.57 0.63 0.6 0.57 0.62 0.6 0.57 1.35 1.55
80 6 0.67 0.63 0.61 0.66 0.63 0.6 0.65 0.62 0.6
8 0.7 0.67 0.65 0.69 0.67 0.65 0.68 0.66 0.65 Soiling
rate
high
10 0.72 0.7 0.68 0.71 0.69 0.67 0.71 0.69 0.67 1.65 2.15
Fitting at center of room
1 0.29 0.23 0.19 0.28 0.23 0.19 0.28 0.23 0.19
1.2 0.35 0.29 0.25 0.34 0.29 0.25 0.33 0.28 0.25
1.5 0.42 0.37 0.33 0.41 0.36 0.33 0.41 0.36 0.33
2 0.52 0.47 0.44 0.51 0.47 0.44 0.5 0.47 0.44

SEMI DIRECT 1 0.27 0.21 0.17 0.25 0.2 0.16 0.23 0.19 0.15
1.2 0.32 0.26 0.21 0.3 0.24 0.2 0.27 0.23 0.19
1.5 0.38 0.32 0.27 0.35 0.3 0.26 0.33 0.28 0.24
2 0.46 0.4 0.35 0.43 0.37 0.33 0.39 0.35 0.32
2.5 0.51 0.45 0.41 0.47 0.43 0.39 0.44 0.4 0.36 Soiling
rate for
low
20 3 0.55 0.5 0.45 0.51 0.47 0.43 0.47 0.44 0.4 1.25 1.4
| 4 0.6 0.56 0.52 0.56 0.52 0.49 0.52 0.49 0.46
88 5 0.64 0.6 0.56 0.6 0.56 0.53 0.56 0.53 0.5 Soiling
rate
normal
 | 6 0.66 0.63 0.59 0.62 0.59 0.56 0.58 0.56 0.53 1.45 1.8
68 8 0.7 0.67 0.64 0.66 0.63 0.61 0.61 0.59 0.57 Soiling
rate
high
10 0.72 0.69 0.67 0.68 0.65 0.63 0.64 0.62 0.6
Fitting at Room Center
1 0.29 0.23 0.19 0.27 0.22 0.18 0.25 0.2 0.17
1.2 0.34 0.28 0.24 0.32 0.27 0.23 0.3 0.25 0.22
1.5 0.41 0.36 0.31 0.39 0.34 0.3 0.36 0.32 0.28
2 0.51 0.46 0.42 0.48 0.43 0.4 0.45 0.41 0.38

DIRECT 1 0.27 0.21 0.17 0.23 0.19 0.15 0.2 0.16 0.13
INDIRECT 1.2 0.31 0.25 0.21 0.27 0.22 0.19 0.23 0.19 0.17
1.5 0.37 0.31 0.27 0.32 0.27 0.24 0.8 0.24 0.21
2 0.44 0.39 0.35 0.39 0.34 0.31 0.33 0.3 0.27
2.5 0.49 0.44 0.4 0.43 0.39 0.36 0.32 0.34 0.31 Soiling
rate low
41 3 0.53 0.48 0.44 0.47 0.43 0.39 0.4 0.37 0.35 1.25 1.4
| 4 0.58 0.54 0.5 0.51 0.48 0.45 0.44 0.42 0.39
90 5 0.62 0.58 0.55 0.54 0.51 0.49 0.47 0.45 0.43 Soiling
rate
normal
| 6 0.64 0.61 0.58 0.56 0.54 0.51 0.49 0.47 0.45 1.45 1.8
49 8 0.67 0.64 0.62 0.59 0.57 0.55 0.52 0.5 0.49 Soiling
rate
high
10 0.69 0.67 0.65 0.61 0.59 0.58 0.53 0.52 0.51

1 0.28 0.22 0.19 0.25 0.2 0.17 0.21 0.18 0.15

1.2 0.33 0.27 0.23 0.29 0.24 0.21 0.25 0.22 0.19
1.5 0.39 0.34 0.3 0.35 0.3 0.27 0.3 0.27 0.24
2 0.48 0.43 0.39 0.42 0.39 0.35 0.37 0.34 0.32

Fluorescent Utilization Factor New Conditions Maintenance Factor

Lamps
Type of fitting v% k rc 0.7 0.5 0.3 Clean Clean Clean
rw 0.5 0.3 0.1 0.5 0.3 0.1 0.5 0.3 0.1 Once once once
Fluorescent 1 0.27 0.2 0.16 0.24 0.18 0.15 0.21 0.16 0.13 Yearly every every
lamp on 1.2 0.31 0.25 0.2 0.28 0.22 0.18 0.25 0.2 0.16 2 Years 3 Years
mounting rail 1.5 0.37 0.31 0.26 0.33 0.28 0.12 0.29 0.25 0.21
2 0.45 0.39 0.34 0.4 0.35 0.31 0.35 0.31 0.28
 2.5 0.5 0.44 0.39 0.45 0.4 0.36 0.4 0.36 0.32 Soiling rate
low
33 3 0.54 0.48 0.44 0.48 0.44 0.4 0.43 0.39 0.36 1.25 1.4 1.55
| 4 0.6 0.55 0.5 0.54 0.5 0.46 0.48 0.44 0.41 Soiling rate
normal
93 5 0.63 0.59 0.55 0.57 0.53 0.5 0.51 0.48 0.45 1.45 1.8 2.05
| 6 0.66 0.62 0.59 0.6 0.56 0.53 0.53 0.51 0.48 Soiling rate
high
60 8 0.7 0.66 0.63 0.63 0.6 0.58 0.57 0.54 0.52
10 0.72 0.69 0.66 0.65 0.63 0.61 0.59 0.57 0.55
Fitting at Room Center
1 0.28 0.22 0.17 0.25 0.2 0.16 0.22 0.18 0.14
1.2 0.33 0.27 0.22 0.29 0.24 0.2 0.26 0.22 0.18
1.5 0.4 0.34 0.29 0.36 0.3 0.27 0.32 0.28 0.24
2 0.49 0.43 0.38 0.44 0.39 0.35 0.39 0.36 0.32

DIRECT 1 0.29 0.24 0.2 0.29 0.23 0.2 0.28 0.23 0.2
Through fitting 1.2 0.35 0.29 0.25 0.34 0.28 0.25 0.33 0.28 0.24
with fluorescent 1.5 0.41 0.36 0.31 0.41 0.35 0.31 0.4 0.35 0.31
lamps 2 0.5 0.45 0.41 0.49 0.44 0.41 0.48 0.44 0.41
2.5 0.55 0.5 0.47 0.54 0.5 0.46 0.53 0.5 0.46 Soiling rate
low
0 3 0.59 0.55 0.51 0.58 0.54 0.51 0.58 0.54 0.51 X X X
| 4 0.65 0.61 0.58 0.64 0.6 0.56 0.65 0.6 0.57
82 5 0.68 0.65 0.62 0.67 0.64 0.62 0.66 0.64 0.62 Soiling rate
normal
| 6 0.7 0.67 0.65 0.69 0.67 0.65 0.69 0.67 0.65 1.4 1.7 1.9
82 8 0.73 0.71 0.69 0.72 0.71 0.69 0.7 0.7 0.69 Soiling rate
high
10 0.75 0.73 0.71 0.74 0.73 0.71 0.74 0.72 0.71 1.85 2.55 3.1
Fitting at Room Center
1 0.32 0.26 0.22 0.31 0.26 0.22 0.3 0.26 0.22
1.2 0.38 0.33 0.29 0.37 0.32 0.29 0.37 0.32 0.29
1.5 0.46 0.41 0.38 0.46 0.41 0.38 0.45 0.41 0.38
2 0.57 0.53 0.5 0.57 0.53 0.5 0.56 0.53 0.5

DIRECT 1 0.25 0.2 0.17 0.22 0.18 0.15 0.19 0.15 0.13
INIRECT 1.2 0.3 0.24 0.21 0.26 0.21 0.18 0.22 0.18 0.13
with louver 1.5 0.35 0.3 0.26 0.3 0.26 0.23 0.26 0.23 0.2
2 0.42 0.37 0.33 0.36 0.33 0.29 0.31 0.28 0.26
2.5 0.47 0.42 0.38 0.4 0.37 0.34 0.34 0.32 0.29 Soiling rate low
43 3 0.5 0.46 0.42 0.43 0.4 0.37 0.37 0.34 0.32 1.35 1.55 1.75
 | 4 0.55 0.51 0.48 0.47 0.44 0.42 0.4 0.38 0.36 Soiling rate
normal
85 5 0.58 0.54 0.51 0.5 0.47 0.45 0.43 0.41 0.39 1.65 2.15 2.5
| 6 0.6 0.57 0.54 0.52 0.5 0.48 0.44 0.43 0.41 Soiling rate
high
42 8 0.62 0.6 0.58 0.54 0.53 0.51 0.47 0.45 0.44 X X X
10 0.64 0.68 0.6 0.56 0.54 0.53 0.48 0.47 0.46
Fitting at Room Center
1 0.27 0.22 0.18 0.23 0.19 0.16 0.2 0.17 0.14
1.2 0.31 0.26 0.23 0.27 0.23 0.2 0.24 0.2 0.18
1.5 0.38 0.33 0.29 0.33 0.29 0.26 0.28 0.25 0.23
2 0.45 0.41 0.37 0.4 0.38 0.34 0.34 0.32 0.3

SEMI- 1 0.24 0.19 0.15 0.2 0.16 0.13 0.16 0.13 0.11
INDIRECT 1.2 0.28 0.23 0.19 0.23 0.19 0.16 0.19 0.16 0.13
with louver 1.5 0.33 0.28 0.24 0.28 0.23 0.2 0.22 0.19 0.17
2 0.4 0.35 0.31 0.33 0.29 0.26 0.27 0.24 0.22
2.5 0.44 0.39 0.35 0.37 0.33 0.3 0.3 0.27 0.25 Soiling rate
low
51 3 0.47 0.43 0.39 0.4 0.36 0.33 0.32 0.3 0.8 1.4 1.65 1.85
| 4 0.52 0.48 0.45 0.44 0.41 0.38 0.36 0.33 0.31 Soiling
rate normal
85 5 0.55 0.51 0.48 0.46 0.44 0.41 0.38 0.36 0.34 1.7 2.25 2.65
| 6 0.57 0.54 0.51 0.48 0.46 0.44 0.39 0.38 0.36 Soiling
rate high
34 8 0.6 0.57 0.55 0.51 0.49 0.47 0.41 0.4 0.39 X X X
10 0.62 0.59 0.57 0.52 0.51 0.49 0.43 0.42 0.41
Fitting at Room Center
1 0.25 0.2 0.16 0.21 0.17 0.14 0.17 0.14 0.12
1.2 0.29 0.24 0.2 0.25 0.21 0.18 0.2 0.17 0.15
1.5 0.35 0.3 0.26 0.29 0.25 0.23 0.24 0.21 0.19
2 0.42 0.37 0.34 0.35 0.32 0.29 0.29 0.27 0.25

INDIRECT 1 0.12 0.1 0.08 0.08 0.06 0.05 0.04 0.04 0.03
Recess with 1.2 0.14 0.11 0.09 0.09 0.07 0.06 0.05 0.04 0.04
Fluorescent lamps 1.5 0.17 0.13 0.12 0.11 0.09 0.08 0.06 0.05 0.04
2 0.2 0.17 0.15 0.13 0.11 0.1 0.07 0.06 0.06
2.5 0.21 0.2 0.17 0.14 0.13 0.12 0.08 0.07 0.07 Soiling rate
low
70 3 0.23 0.21 0.18 0.15 0.14 0.12 0.08 0.08 0.07 1.25 1.45 X
| 4 0.25 0.23 0.21 0.17 0.15 0.14 0.09 0.09 0.08 Soiling rate
normal
70 5 0.27 0.25 0.23 0.18 0.16 0.15 0.1 0.09 0.09 X X X
| 6 0.28 0.26 0.24 0.18 0.17 0.16 0.1 0.1 0.09 Soiling rate
normal
0 8 0.29 0.27 0.25 0.19 0.18 0.17 0.11 0.1 0.1 X X X
10 0.31 0.28 0.27 0.2 0.19 0.18 0.11 0.11 0.1
SELECTION OF MOTOR STARTER & FUSE FREE BREAKER

DIRECT ON LINE STARTER ( DOL starter )

1. The method of motor starting is direct on line under AC3 operating conditions according to IEC 158-1.
2. The motor is Hitachi standard type squirrel cage 4 pole induction motor.
3. The heater range for the thermal overload relays are selected from the motor's full load current.
4. The selection of FFB is on the basis of 600% current for 10 sec.

DOL Starter in rated 220V 3 Phase 50Hz

Rating Rating Full_ Type_of_Magnet_Starter Thermal_OL Heater_ NH_ Type_S Type_F_Series Rated_ Wire_Size
_HP _KW Load Range(A) Fuse _Series Current (sq-mm)
(A) (A)
0.13 0.1 0.78 K10NEP2_or_K11NEP2 TR11-1E 0.6-1.0 4 S-305 F-50K_or_F-50F 3 1
0.27 0.2 1.3 K10NEP2_or_K11NEP2 TR11-1E 0.8-1.6 6 S-305 F-50K_or_F-50F 3 1
0.33 0.25 1.2 K10NEP2_or_K11NEP2 TR11-1E 0.8-1.6 6 S-305 F-50K_or_F-50F 3 1
0.5 0.4 1.7 K10NEP2_or_K11NEP2 TR11-1E 1.6-3.2 10 S-305 F-50K_or_F-50F 5 1
0.75 0.55 2.3 K10NEP2_or_K11NEP2 TR11-1E 1.6-3.2 10 S-305 F-50K_or_F-50F 5 1
1 0.75 2.9 K10NEP2_or_K11NEP2 TR11-1E 2.5-5.0 10 S-305 F-50K_or_F-50F 8 1
1.5 1.1 4.2 K10NEP2_or_K11NEP2 TR11-1E 2.5-5.0 10 S-305 F-50K_or_F-50F 8 1
2 1.5 5.8 K10NEP2_or_K11NEP2 TR11-1E 4.5-9.0 16 S-305 F-50K_or_F-50F 15 1
3 2.2 7.8 K10NEP2_or_K11NEP2 TR11-1E 6-12 20 S-305 F-50K_or_F-50F 20 1.5
4 3 10.5 K15CNEP3_or_K15BNEP TR20-1E 6-12 25 S-305 F-50K_or_F-50F 20 1.5
3
5 3.7 13 K15CNEP3_or_K15BNEP TR20-1E 12-18 35 S-305 F-50K_or_F-50F 30 1.5
3
5.5 4 14 K15CNEP3_or_K15BNEP TR20-1E 12-18 35 S-305 F-50K_or_F-50F 30 1.5
3
7.5 5.5 20 K15CNEP3_or_K15BNEP TR20-1E 16-24 50 S-50 F-50K_or_F-50F 50 4
3
10 7.5 25 K20BNEP3 TR40-1E 22-34 63 S-50 F-50K_or_F-50F 50 4
15 11 36 K25BNEP3 TR40-1E 32-48 80 S-100S F-100G 75 10
20 15 50 K30BNEP3 TR40-1E 45-65 100 S-100S F-100G 100 10
25 18.5 62 K50N-EP3 TR100-1E 45-65 125 S-100S F-100G 100 16
30 22 72 K60N-EP3 TR100-1E 55-80 160 S-225S F-225F_or_F-225KB 150 25
40 30 100 K100N-EP3 TR100-1E 90-120 200 S-225S F-225F_or_F-225KB 200 35
50 37 120 K120N-EP3 TR100-1E 110-150 250 S-225S F-225F_or_F-225KB 225 50
60 45 145 K150N-EP3 TR100-1E 110-150 250 S-225S F-225F_or_F-225KB 225 70
75 55 180 K200N-EP3 TR20E-1 1.6-3.2 400 S-400S F-400F 350 95
_with_CT100N
100 75 240 K250N-EP3 TR20E-1 1.6-3.2 500 S-600S F-600F 500 120
_with_CT100N
 125 90 290 K300N-EP3 TR20E-1 2.5-5 800 S-600S F-600F 600 185
_with_CT100N
150 110 350 K400N-EP3 TR20E-1 2.5-5 800 S-800S F-800K 700 240
_with_CT100N
180 132 410 K600N-EP3 TR20E-1 2.5-5 800 S-800S F-800K 800 240
_with_CT100N
220 160 520 K600N-EP3 TR20E-1 4.5-9 800 N.A U-800 800 240
_with_CT100N
270 200 N.A N.A N.A N.A N.A
340 250 N.A N.A N.A N.A N.A

DOL Starter in rated 380V 3 Phase 50Hz

Rating Rating Full_ Type_of_Magnet_Starter Thermal_OL Heater_ NH_ Type_S_ Type_F_Series Rated Wire_
_HP _KW Load Range(A) Fuse Series _Cur Size
(A) rent (sq-mm
(A)
0.13 0.1 0.42 K10NEP2_or_K11NEP2 TR11-1E 0.35-0.65 4 S-30SZ F-50K_or_F-50F 3 1
0.27 0.2 0.64 K10NEP2_or_K11NEP2 TR11-1E 0.6-1.0 4 S-30SZ F-50K_or_F-50F 3 1
0.33 0.25 0.7 K10NEP2_or_K11NEP2 TR11-1E 0.6-1.0 4 S-30SZ F-50K_or_F-50F 3 1
0.5 0.4 1 K10NEP2_or_K11NEP2 TR11-1E 0.8-1.6 6 S-30SZ F-50K_or_F-50F 3 1
0.75 0.55 1.3 K10NEP2_or_K11NEP2 TR11-1E 0.8-1.6 6 S-30SZ F-50K_or_F-50F 3 1
1 0.75 1.7 K10NEP2_or_K11NEP2 TR11-1E 1.6-3.2 6 S-30SZ F-50K_or_F-50F 3 1
1.5 1.1 2.4 K10NEP2_or_K11NEP2 TR11-1E 1.6-3.2 8 S-30SZ F-50K_or_F-50F 5 1
2 1.5 3.3 K10NEP2_or_K11NEP2 TR11-1E 2.5-5.0 10 S-30SZ F-50K_or_F-50F 5 1
3 2.2 4.5 K10NEP2_or_K11NEP2 TR11-1E 2.5-5.0 10 S-30SZ F-50K_or_F-50F 8 1
4 3 6.2 K10NEP2_or_K11NEP2 TR11-1E 4.5-9.0 16 S-30SZ F-50K_or_F-50F 15 1
5 3.7 7.5 K10NEP2_or_K11NEP2 TR11-1E 4.5-9.0 20 S-30SZ F-50K_or_F-50F 20 1.5
5.5 4 8.5 K15CNEP3_or_K15BNEP3 TR20-1E 6-12 20 S-30SZ F-50K_or_F-50F 20 1.5
7.5 5.5 11.5 K15CNEP3_or_K15BNEP3 TR20-1E 6-12 35 S-30SZ F-50K_or_F-50F 30 1.5
10 7.5 14.5 K15CNEP3_or_K15BNEP3 TR40-1E 12-18 35 S-30SZ F-50K_or_F-50F 30 1.5
15 11 21 K20BNEP3 TR20-1E 16-24 50 S-50S F-50K_or_F-50F 50 4
20 15 29 K25BNEP3 TR40-1E 22-34 63 S-50S F-50K_or_F-50F 50 6
25 18.5 36 K30BN-EP3 TR40-1E 32-48 80 S-100S F-100G 75 10
30 22 42 K30BN-EP3 TR40-1E 32-48 80 S-100S F-100G 75 10
40 30 55 K50N-EP3 TR100-1E 45-65 100 S-100S F-100G 100 16
50 37 68 K60N-EP3 TR100-1E 55-80 160 S-225S F-225F_or_F- 150 25
225KB
60 45 85 K100N-EP3 TR100-1E 65-95 160 S-225S F-225F_or_F- 150 25
 225KB
75 55 105 K120N-EP3 TR100-1E 90-120 200 S-225S F-225F_or_F- 175 35
225KG
100 75 140 K150N-EP3 TR100-1E 110-150 250 S-225S F-225F_or_F- 225 50
225KG
125 90 165 K200N-EP3 TR20E- 1.0-1.8 315 S-225S F-225F_or_F- 225 70
1_with_CT100 225KG
N
150 110 200 K250N-EP3 TR20E- 1.6-3.2 400 S-400S F-400F 350 95
1_with_CT100
N
180 132 230 K300N-EP3 TR20E- 1.6-3.2 500 S-600S F-600F 500 120
1_with_CT100
N
220 160 300 K400N-EP3 TR20E- 2.5-5 800 S-600S F-600F 500 185
1_with_CT100
N
270 200 370 K400N-EP3 2.5-5 800 S- F-800K 700 240
TR20E-1_with_CT100N 800S
340 250 475 K600N-EP3 2.5-5 800 S- F-800K 800 240
TR20E-1_with_CT100N 800S

DOL Starter in rated 415V 3 Phase 50Hz

Rating_ Rating_ Full_Load Type_of_Magnet_Starter Thermal_OL Heater_ NH_ Type_S Type_F_Series Rated_ Wire_
HP KW Range(A) Fuse _Series Current Size
(A) (A) (sq-mm
0.13 0.1 0.34 K10NEP2_or_K11NEP2 TR11-1E 0.2-0.4 4 S-30SZ F-50K_or_F-50F 3 1
0.27 0.2 0.63 K10NEP2_or_K11NEP2 TR11-1E 0.6-1.0 4 S-30SZ F-50K_or_F-50F 3 1
0.33 0.25 0.7 K10NEP2_or_K11NEP2 TR11-1E 0.6-1.0 4 S-30SZ F-50K_or_F-50F 3 1
0.5 0.4 1 K10NEP2_or_K11NEP2 TR11-1E 0.8-1.6 6 S-30SZ F-50K_or_F-50F 3 1
0.75 0.55 1.3 K10NEP2_or_K11NEP2 TR11-1E 0.8-1.6 6 S-30SZ F-50K_or_F-50F 3 1
1 0.75 1.7 K10NEP2_or_K11NEP2 TR11-1E 1.6-3.2 6 S-30SZ F-50K_or_F-50F 3 1
1.5 1.1 2.5 K10NEP2_or_K11NEP2 TR11-1E 1.6-3.2 8 S-30SZ F-50K_or_F-50F 5 1
2 1.5 3.4 K10NEP2_or_K11NEP2 TR11-1E 2.5-5.0 10 S-30SZ F-50K_or_F-50F 5 1
3 2.2 4.5 K10NEP2_or_K11NEP2 TR11-1E 2.5-5.0 10 S-30SZ F-50K_or_F-50F 8 1
4 3 5.8 K10NEP2_or_K11NEP2 TR11-1E 4.5-9.0 16 S-30SZ F-50K_or_F-50F 15 1
5 3.7 7.2 K10NEP2_or_K11NEP2 TR11-1E 4.5-9.0 20 S-30SZ F-50K_or_F-50F 20 1.5
5.5 4 8.5 K15CNEP3_or_K15BNEP3 TR20-1E 6-12 20 S-30SZ F-50K_or_F-50F 20 1.5
7.5 5.5 11.5 K15CNEP3_or_K15BNEP3 TR20-1E 6-12 35 S-30SZ F-50K_or_F-50F 30 1.5
10 7.5 14 K15CNEP3_or_K15BNEP3 TR20-1E 12-18 35 S-30SZ F-50K_or_F-50F 30 1.5
15 11 21 K20BNEP3 TR20-1E 16-24 50 S-50S F-50K_or_F-50F 50 4
20 15 28 K25BNEP3 TR40-1E 22-34 63 S-50S F-50K_or_F-50F 50 6
 25 18.5 35 K30BN-EP3 TR40-1E 32-48 80 S-100S F-100G 75 10
30 22 40 K30BN-EP3 TR40-1E 32-48 80 S-100S F-100G 75 10
40 30 52 K50N-EP3 TR100-1E 45-65 100 S-100S F-100G 100 16
50 37 62 K60N-EP3 TR100-1E 55-80 160 S-225S F-100G 100 16
60 45 80 K100N-EP3 TR100-1E 65-95 160 S-225S F-225F_or_F- 150 25
225KB
75 55 95 K120N-EP3 TR100-1E 90-120 200 S-225S F-225F_or_F- 175 35
225KB
100 75 130 K150N-EP3 TR100-1E 110-150 250 S-225S F-225F_or_F- 225 50
225KB
125 90 160 K200N-EP3 TR20- 1.0-1.8 315 S-225S F-225F_or_F- 225 70
1E_with_CT1 225KB
00N
150 110 195 K250N-EP3 TR20- 1.6-3.2 400 S-400S F-400F 350 95
1E_with_CT1
00N
180 132 230 K300N-EP3 TR20- 1.6-3.2 500 S-600S F-600F 500 120
1E_with_CT1
00N
220 160 275 K400N-EP3 TR20- 2.5-5 800 S-600S F-600F 500 150
1E_with_CT1
00N
270 200 345 K400N-EP3 TR20- 2.5-5 800 S-800S F-800K 700 185
1E_with_CT100N
340 250 428 K600N-EP3 TR20- 2.5-5 800 S-800S F-800K 800 240
1E_with_CT100N
STAR-DELTA STARTER
1. The Star-Delta starter employ 3-contactor system.
2. The motor is a Hitachi standard type squirrel cage 4-pole induction motor.
3. The heater range for thermal overload relay are selected from 1/√3 = 0.58 of the motor full load current.
4. The said wire size indicates IV wire which is able to be connected to the MS & MCd terminals. As for source lone, refer to direct on line stating.

Star Delta Starter in rated 220V 3 Phase 50Hz

Rating Rating Full Type Magnet Thermal Heater Type of Type of Delta NH S-Series F-Series Rated Wire
HP KW Load Starter OL Range Star MCs MCs Fuse Current Size
(A) (A) (A) (sqmm)
5 3.7 13 K10N-EP2_or_ TR11-1E 6-12 K11N-EP K11N-EP 35 S-30S F-50F_or_F- 30 2
K11N-EP2 50K
5.5 4 14 K10N-EP2_or_ TR11-1E 6-12 K11N-EP K11N-EP 35 S-30S F-50F_or_F- 30 2
K11N-EP2 50K
7.7 5.5 20 K15B-N-EP3 TR20-1E 9-13 K15-BN-EP K15-BN-EP 35 S-50 S-50 50 2
10 7.5 25 K20B-N-EP3 TR20-1E 12-18 K15-BN-EP K20-BN-EP 50 S-50 S-50 50 4
 15 11 36 K25BN-EP3 TR40-1E 16-24 K15BN-EP K20BN-EP 63 S-100S F-100G 75 6
20 15 50 K30BN-EP3 TR40-1E 22-34 K20BN-EP K30BN-EP 80 S-100S F-100G 100 10
25 18.5 62 K30BN-EP3 TR40-1E 32-48 K25BN-EP K30BN-EP 100 S-225S F-225F 125 10
30 22 72 K50N-EP3 TR-100-1E 32-48 K25BN-EP K50BN-EP 100 S-225S F-225F 150 10
40 30 100 K60N-EP3 TR-100-1E 45-65 K30BN-EP K60BN-EP 125 S-225S F-225F 200 16
50 37 120 K100N-EP3 TR-100-1E 55-80 K50N-EP K100N-EP 160 S-225S F-225F 225 25
60 45 145 K120N-EP3 TR-100-1E 65-95 K50N-EP K120N-EP 200 S-400S F-400F 350 35
75 55 180 K150N-EP3 TR100-1E 90-120 K60N-EP K150N-EP 200 S-400S F-400F 400 35
100 75 240 K200N-EP3 TR20- 90-120 K120N-EP K200N-EP 0 S-600S F-600F 0 0
1E_with_
CT100N
125 90 290 K250N-EP3 TR20- 1.0-1.8 K150N-EP K250N-EP 400 S-800S F-800F 700 70
1E_with_
CT100N
150 110 350 K300N-EP3 TR20- 1.6-3.2 K200N-EP K300N-EP 400 S-800S F-800F 800 120
1E_with_
CT100N
180 132 410 K400N-EP3 TR20- 1.6-3.2 K250N-EP K400N-EP 500 N/A U-800 800 150
1E_with_
CT100N
220 160 520 K400N-EP3 TR20- 2.5-5.0 K300N-EP K400N-EP 630 N/A U-1200 1000 185
1E_with_
CT100N
270 200 710 K600N-EP3 TR20- 2.5-5 K300N-EP K600N-EP 800 N/A U-1200 1200 325
1E_with_
CT100N

340 250 823 K600N-EP3 TR20- 2.5-5.0 K400N-EP K600N-EP 800 N/A U-1200 1200 325
1E_with_C
T100N

Star Delta Starter in rated 380V 3 Phase 50Hz

Rating Rating Full Type Magnet Starter Thermal OL Heater Type of Star Type of NH S-Series F-Series Rated Wire
HP KW Load Range MCs Delta MCs Fuse Current Size
(A) (A) (A) (sqmm)
5 3.7 7.5 K10N-EP2_or_ K11N- TR11-1E 2.5-5.0 K11N-EP K11N-EP 16 S-30S F-50F_or_F- 20 1
EP2 50K
5.5 4 8.5 K10N-EP2_or_ K11N- TR11-1E 4.5-9.0 K11N-EP K11N-EP 16 S-30S F-50F_or_F- 20 1
EP2 50K
7.7 5.5 11.5 K15B-N-EP3 TR11-1E 4.5-9.0 K15-BN-EP K11N-EP 20 S-30S F-50F_or_F- 30 1
50K
 10 7.5 14.5 K15B-N-EP3 TR20-1E 6-12 K15-BN-EP K11N-EP 35 S-30S F-50F_or_F- 30 1.5
50K
15 11 21 K15B-N-EP3 TR20-1E 12-18 K15BN-EP K11N-EP 35 S-100S F-50F_or_F- 50 1.5
50K
20 15 29 K20BN-EP3 TR20-1E 12-18 K15BN-EP K20BN-EP 50 S-100S F-50F_or_F- 50 2.5
50K
25 18.5 36 K25BN-EP3 TR40-1E 16-24 K20BN-EP K25BN-EP 50 S-225S F-100G 75 4
30 22 42 K30BN-EP3 TR40-1E 22-34 K25BN-EP K30BN-EP 63 S-225S F-100G 100 6
40 30 55 K30BN-EP3 TR40-1E 22-34 K25BN-EP K30BN-EP 63 S-225S F-100G 100 6
50 37 68 K50BN-EP3 TR-100-1E 32-48 K30N-EP K50N-EP 100 S-225S F-225F_or_F- 125 10
225KB
60 45 85 K50BN-EP3 TR-100-1E 45-65 K50N-EP K50N-EP 100 S-225S F-225F_or_F- 150 10
225KB
75 55 105 K60N-EP3 TR-100-1E 55-80 K50N-EP K60N-EP 125 S-225S F-225F_or_F- 175 16
225KB
100 75 140 K100N-EP3 TR-100-1E 65-95 K60N-EP K100N-EP 160 S-225S F-225F_or_F- 225 25
225KB
125 90 165 K120N-EP3 TR-100-1E 90-120 K100N-EP K120N-EP 200 S-400S F-400F 350 35
150 110 200 K150N-EP3 TR-100-1E 110-150 K120N-EP K150N-EP 250 S-400S F-400F 400 50
180 132 150 K200N-EP3 TR20- 1.0-1.8 K200N-EP K150N-EP 250 S-600S F-600F 500 50
1E_with_CT1
000
220 160 300 K250N-EP3 TR20- 1.6-3.2 K200N-EP K250N-EP 315 S-600S F-600F 600 95
1E_with_CT1
000
270 200 370 K300N-EP3 TR20- 1.6-3.2 K200N-EP K300N-EP 400 S-800S F-800K 800 120
1E_with_CT1
000
340 250 475 K400N-EP3 TR20- 1.6-3.2 K300N-EP K400N-EP 630 N/A U-800 800 150
1E_with_CT1
000

Star Delta Starter in rated 415V 3 Phase 50Hz

Rating Rating Full Type Magnet Starter Thermal OL Heater Type of Star Type of NH S-Series F-Series Rated Wire
HP KW Load Range MCs Delta MCs Fuse Current Size
(A) (A) (A) (sqmm)
5 3.7 7.2 K10N-EP2_or_ K11N- TR11-1E 2.5-5.0 K11N-EP K11N-EP 16 S-30SZ F-50F_or_F- 20 1
EP2 50K
5.5 4 8.5 K10N-EP2_or_ K11N- TR11-1E 4.5-9.0 K11N-EP K11N-EP 16 S-30S F-50F_or_F- 20 1
EP2 50K
7.7 5.5 11.5 K15B-N-EP3 TR20-1E 4.5-9.0 K15-BN-EP K15-BN- 20 S-30S F-50F_or_F- 30 1
EP 50K
 10 7.5 14 K15B-N-EP3 TR20-1E 6-12 K15-BN-EP K15-BN- 35 S-30S F-50F_or_F- 30 1.5
EP 50K
15 11 21 K15B-N-EP3 TR20-1E 12-18 K15BN-EP K11N-EP 35 S-30SZ F-50F_or_F- 50 1.5
50K
20 15 28 K20BN-EP3 TR20-1E 12-18 K15BN-EP K20BN-EP 50 S-30SZ F-50F_or_F- 50 2.5
50K
25 18.5 35 K25BN-EP3 TR40-1E 16-24 K20BN-EP K25BN-EP 50 S-100S F-100G 75 4
40 30 52 K30BN-EP3 TR40-1E 22-34 K25BN-EP K30BN-EP 63 S-100S F-100G 100 6
50 37 62 K50BN-EP3 TR100-1E 32-48 K30BN-EP K50N-EP 100 S-225S F-225F_or_F- 125 10
225KB
60 45 80 K50BN-EP3 TR-100-1E 45-65 K50N-EP K50N-EP 100 S-225S F-225F_or_F- 150 10
225KB
75 55 95 K60BN-EP3 TR-100-1E 45-65 K50N-EP K60N-EP 125 S-225S F-225F_or_F- 175 16
225KB
100 75 130 K100N-EP3 TR-100-1E 65-95 K60N-EP K100N-EP 160 S-225S F-225F_or_F- 225 25
225KB
125 90 160 K120N-EP3 TR-100-1E 65-95 K100N-EP K120N-EP 200 S-400S F-400F 350 35
150 110 195 K150N-EP3 TR-100-1E 90-120 K120N-EP K150N-EP 250 S-400S F-400F 400 50
180 132 230 K200N-EP3 TR20_with_ 1.0-1.8 K200N-EP K200N-EP 250 S-600S F-600F 500 50
CT100N
220 160 275 K250N-EP3 TR20- 1.0-1.8 K200N-EP K250N-EP 315 S-600S F-600F 600 70
1E_with_CT1
000
270 200 345 K300N-EP3 TR20- 1.6-3.2 K200N-EP K300N-EP 400 S-800S F-800K 800 95
1E_with_CT1
000
340 250 428 K400N-EP3 TR20- 1.6-3.2 K300N-EP K400N-EP 630 S-800S U-800 800 150
1E_with_CT1
000
30 22 40 K30BN-EP3 TR40-1E 22-34 K25BN-EP K30BN-EP 63 S-100S F-100G 100 4

Maximum Demand Rule of Thumb Samples Table

Approx. Incoming Actual % Max.Load Actual % Type Industry type
Amp
48.3 5000 48.3 2500 46.73 Submains Gul Technologies ( PCB industry )
94.39 3200 94.39 1000 92 Main DB United Cement Silo Erection Project ( Mostly Motors Load Industry )
65.87 2500 43.8 1250 28.09 Main DBs Gul Technologies ( PCB industry )
2500 66.22 600 59.84 Gul Technologies ( PCB industry )
2500 62.9 600 56.29 Gul Technologies ( PCB industry )
2500 90.58 500 88.5 Gul Technologies ( PCB industry )
 51.95 1600 51.44 800 34.63 Main MVSB Insulpak Styrotek
( Chemical & Easy Burning Industry )
1600 52.46 800 35.5 Insulpak Styrotek
( Chemical & Easy Burning Industry )
53.11 1200 63.66 300 56.78 E.S.B Gul Technologies ( PCB industry )
(emergency)
1200 43.07 400 33.53 Gul Technologies ( PCB industry )
1200 52.6 MSB Citi Bank ( Bank )
49.68 1000 55.5 MVSB SCS (Software Co.)
1000 43.86 Citi Bank ( Bank )
44.57 630 50.41 315 33.69 Silo Feed United Cement Silo Erection Project
MCC1 ( Mostly Motors Load Industry )
630 38.74 80 33.57 Discharge United Cement Silo Erection Project
MCC2 ( Mostly Motors Load Industry )
50.36 600 57.43 225 45.45 Gul Technologies ( PCB industry )
600 43.29 300 27.62 Submains ST Computer System & Services Ltd.
40.8 400 42 Submains SCS (Software Co.)
400 39.6 63 35.9 Power Cee Citi Bank ( Bank )
Form unit DB
45.45 300 45.45 100 35.7 Insulpak Styrotek
( Chemical & Easy Burning Industry )
54.075 250 28.28 160 12.43 ST Computer System & Services Ltd.
250 79.87 100 70.84 Motor Load Ssangyong Cement
45 225 45 150 21.43 Gul Technologies ( PCB industry )

Approx. Incoming Actual % Max.Load Actual % Type Industry type

Amp
59.53 200 40.65 63 27.84 ST Computer System & Services Ltd.
200 68.96 60 60.87 MVSB Yimeido Cosmetic P.L
( Chemical Industry )
200 68.98 60 60.87 Main DB Europe Kitchen ( Restaurant )
69.44 125 69.44 60 50 Gul Technologies ( PCB industry )
49.8 100 33.33 60 16.67 Isolator Insulpak Styrotek
( Chemical & Easy Burning Industry )
 49.8 100 70.42 60 48.78 Insulpak Styrotek
( Chemical & Easy Burning Industry )
100 83.33 30 78 Insulpak Styrotek
( Chemical & Easy Burning Industry )
100 24 58 11.73 Gul Technologies ( PCB industry )
100 25.64 60 12.12 Gul Technologies ( PCB industry )
100 66.67 60 44.4 DB-1 United Cement Silo Erection Project ( Mostly Motors Load Industry )
100 55.5 60 83.3 Packing DB-2 United Cement Silo Erection Project ( Mostly Motors Load Industry )
100 69.93 63 46.25 ST Computer System & Services Ltd.
100 54.64 63 30.83 ST Computer System & Services Ltd.
100 54.64 63 30.8 ST Computer System & Services Ltd.
100 53.47 63 40.21 ST Computer System & Services Ltd.
100 47.84 63 25.34 ST Computer System & Services Ltd.
100 47.8 63 25.34 ST Computer System & Services Ltd.
100 41.67 30 33.3 ST Computer System & Services Ltd.
100 40 63 17.87 ST Computer System & Services Ltd.
100 25.97 63 12.25 ST Computer System & Services Ltd.
100 51.8 63 28.46 Submain Metal Component ( Metal Work )
34 75 34 20 27.5 SSQ Gul Technologies ( PCB industry )
50.67 63 67.74 ST Computer System & Services Ltd.
63 62.89 32 53.5 ST Computer System & Services Ltd.
63 61.16 ST Computer System & Services Ltd.
63 55.7 ST Computer System & Services Ltd.
63 50 30 33.33 ST Computer System & Services Ltd.
63 47.37 30 32.03 ST Computer System & Services Ltd.
63 46.67 32 31.06 ST Computer System & Services Ltd.

63 45.98 32 30.77 ST Computer System & Services Ltd.

63 45 ST Computer System & Services Ltd.
63 43.15 ST Computer System & Services Ltd.
63 43.15 ST Computer System & Services Ltd.
63 43.15 ST Computer System & Services Ltd.
63 42.85 32 27.82 ST Computer System & Services Ltd.
63 38.65 30 26.82 ST Computer System & Services Ltd.
63 35.79 32 22.2 ST Computer System & Services Ltd.
63 30.14 ST Computer System & Services Ltd.
63 78.78 Lighting DB Yimeido Cosmetic P.L ( Chemical Industry )
50.67 63 78.75 20 66.67 Isolator,A.C, H.S Precision
Power
63 60.57 30 44.59 M.D.F Room Woodland Telecomm
63 26.25 SSO,DB SGH ( Hospital )
63 25 Light & Power SGH ( Hospital )
DB
63 52.5 Light DB SGH ( Hospital )
63 23.3 30 15 Power DB SGH ( Hospital )
63 52.5 Light DB SGH ( Hospital )
63 81.8 Light/Power/A SGH ( Hospital )
C/Iso DB
63 78.75 Power DB Metal Component ( Metal Work )
60 50 32 31.8 Aircon Insulpak Styrotek ( Chemical & Easy Burning Industry )
60 66.67 30 50 Aircon Insulpak Styrotek ( Chemical & Easy Burning Industry )
38.9 32 36.78 Insulpak Styrotek ( Chemical & Easy Burning Industry )
32 40 ST Computer System & Services Ltd.
32 40 ST Computer System & Services Ltd.
44.4 30 35.29 20 15.38 Submains Insulpak Styrotek ( Chemical & Easy Burning Industry )
30 46.87 Lighting & Insulpak Styrotek ( Chemical & Easy Burning Industry )
Power
30 50 30 50 Aircon Insulpak Styrotek ( Chemical & Easy Burning Industry )
30 33.33 15 20 Insulpak Styrotek ( Chemical & Easy Burning Industry )
30 37.5 20 16.7 ST Computer System & Services Ltd.
30 50 15 33.33 Light & Power SGH ( Hospital )
DB
30 66.67 15 33.3 Submains Citi Bank ( Bank )
30 42.86 Lighting DB Europe Kitchen ( Restaurant )
30 37.5 Lighting DB Metal Component ( Metal Work )
62.5 20 62.5 16 5 Lighting Insulpak Styrotek ( Chemical & Easy Burning Industry )