Ia [industrial automation part 1]

[Didactic Equipment]
[Industrial
Automation
– Part 1
Installation]
[Safety and Security –
Basic Industrial wiring]
Eric Dupont

V1.1 – Confidential Property of CoE EARE
2 [Industrial Automation – Part 1 Installation] [Safety and Security – Basic Industrial wiring]

1
Content
Content
A. THEORETICAL TEACHING CONTENTS ........................................................... 3
SAFETY & SECURITY............................................................................................... 4
PHYSIOLOGICAL EFFECT OF THE ELECTRICITY............................................................................. 5
SAFETY PROCEDURE IN ELECTRICAL WORK (STANDARDS AND BEST PRACTICES)............ 13
INDUSTRIAL WIRING.............................................................................................. 33
DEVICES IN INDUSTRIAL WIRING..................................................................................................... 34
INDUSTRIAL ELECTRICAL DIAGRAM............................................................................................... 47
INDUSTRIAL WIRING - WIRING RULES ............................................................................................ 51
CONDUCTORS AND CABLES ............................................................................................................ 57
ENGINE CHOICE.................................................................................................................................. 65
DC MOTOR ........................................................................................................................................... 82
INDUCTION Motor................................................................................................................................ 89
VARIABLE-Speed .............................................................................................................................. 109
VARIABLE-FREQUENCY DRIVE ...................................................................................................... 119
DIMER - AC-AC Vrms converter with fixed frequency................................................................... 129
MANUAL CONTROL .......................................................................................................................... 140
VISUAL SIGNALLING ........................................................................................................................ 145
COMBINED AUTOMATIC AND MANUAL CONTROL...................................................................... 147
STARTING OF SQUIRREL CAGE MOTORS .................................................................................... 150
B. PRACTICAL TEACHING CONTENTS............................................................ 155
DOL TWO DIRECTION CONTROLLED BY INTEGRATED SYSTEM .............................................. 156
SOFT STARTER ................................................................................................................................. 160
INDUCTION MOTOR CONTROLLED BY VSD.................................................................................. 164
C. ANNEXES & RESOURCES ............................................................................ 169

3
PHYSIOLOGICAL EFFECT OF THE ELECTRICITY
A. Theoretical Teaching Contents

Safety & Security
In this section the topics will be the effect of the electricity on the human Body, the way to
prevent electric shock, the equipment used to protect people.

5

1- PREAMBLE:
As electric current is conducted through a material, any opposition to that flow of electrons
(resistance) results in a dissipation of energy, usually in the form of heat. This is the most
basic and easy-to-understand effect of electricity on living tissue: current makes it heat up. If
the amount of heat generated is sufficient, the tissue may be burnt. The effect is
physiologically the same as damage caused by an open flame or other high-temperature
source of heat, except that electricity has the ability to burn tissue well beneath the skin of a
victim, even burning internal organs.
Another effect of electric current on the body, perhaps the most significant in terms of
hazard, regards the nervous system. By "nervous system" I mean the network of special cells
in the body called "nerve cells" or "neurons" which process and conduct the multitude of
signals responsible for regulation of many body functions. The brain, spinal cord, and
sensory/motor organs in the body function together to allow it to sense, move, respond, think,
and remember.
2- DEFINITIONS
 Internal impedance of the human body (Z1): Impedance between two electrodes in
contact with two parts of the human body, after removing the skin from under the
electrodes.
 Impedance of the skin (Zp): Impedance between an electrode on the skin and the
conductive tissues underneath.
 Total impedance of the human body (ZT): Vectorial sum of the internal impedance
and the impedances of the skin.
 Initial resistance of the human body (Ri): Resistance limiting the peak value of the
current at the moment when the touch voltage occurs.
 Threshold of perception: The minimum value of current which causes any
sensation for the person through which it is flowing.
 Threshold of let-go: The maximum value of current at which a person holding
electrodes can let go of the electrodes.
 Threshold of ventricular fibrillation: The minimum value of current which causes
ventricular fibrillation.
 Heart current factor: The heart current factor relates the electric field strength in the
heart for a given current path to the electric field strength in the heart for a current of
equal magnitude flowing from left hand to feet. Note. - In the heart, the current density
is proportional to the electric field strength.
3- MAIN CAUSES OF ELECTRIC CHOCKS
3.1- MAIN CAUSES ARE:
- Operating mode inappropriate or dangerous (31%),
- Lack of awareness of risks (30%),
- Incomplete application procedures (15%),
- Inadequate training (12%),
- The state of the material (12%),

7
- Soil conditions (11%)Type de contact
In average, 75 % of the Electric choc is from indirect contact, 20 % from direct contact.
Statistic shows that:
- 1/3 of lesions are in multiple places.
- Eyes, arms, hands are the most affected
- 60% of lesions are burns,
- 6 % of lesions are internal.
Accidents related to electricity can cause fires or explosions. The construction industry and
public works, service activities and work temporary and the food industry are among the
most affected. Risk, even if it is better controlled is always present.
3.2- ELECTROCUTION AND ELECTRIC SHOCK
The human body let go by the electric current. A person is electrified when electric
current passes through his body and causes more or less serious injuries. We are talking
about electrocution when electric current causes the death of the person.
3.3- SERIOUSNESS FACTORS
The level of injuries caused by the electric current is due to a combination of several factors:
- The intensity of the current flowing through the human body,
- source of electrical energy (voltage, power) and the environment (insulating or highly
conductive)
- The duration of current flow through the human body,
- The surface area of contact,
- The particular susceptibility of the person subjected to the action of electric current.
4- VALUE OF THE INITIAL RESISTANCE OF THE HUMAN BODY
(RI):
The value of the initial resistance of the human body for a current path hand to hand or hand
to foot and large contact areas can be taken as equal to 500 Ω for the 5% percentile rank.
Touch
Voltage (V)
Values for the total body impedance (Ω) that
are not exceeded for a percentage of
(population)
5% 50% 95%
25 1750 3250 6100
50 1450 2625 4375
75 1250 2200 3500
100 1200 1875 3200
220 1000 1350 2125
700 750 1100 1550
1000 700 1050 1500

The internal impedance of the human body is a function of the current path.
5- CURRENT THROUGH THE BODY AND EFFECTS
The effect of the current in a body can take several forms.
- Thermic effect – Burns (can be done with 10 mA if the contact takes few minutes.
- Tetanizing Effects – When an AC current is going through the body, muscles are
contracted.

9
To calculate the current passing through the
body many parameter have to be taken in
consideration. In order to simplify the
calculation, the Ohm’s law is used with a
body Impedance of 1000 Ω in average.
We know what factors can make a
difference in the effect of current on the
body. One of the various physiological
effects of an electric shock with an
alternating current (AC) is death. Death is a
possibility in three ways - the breathing
centre in the brain is paralyzed, ventricular
fibrillation, and paralysis of the heart.
Vulnerable period: The vulnerable period covers a comparatively small part of the cardiac
cycle during which the heart fibres are in an inhomogeneous state of excitability and
ventricular fibrillation occurs if they are excited by an electric current of sufficient magnitude.
Note. - The vulnerable period corresponds to the first part of the “T-wave” in the
electrocardiogram which is approximately 10% to 20% of the cardiac cycle.
Some experimentation was done on the effect of the electric current on a body. The result is
given to tables and charts hereafter
5.1- EFFECTS IN AC:

11
5.2- EFFECTS IN DC:
6- DIRECT – INDIRECT CONTACT
6.1- DIRECT CONTACT
A direct contact refers to a person coming into contact with a
conductor which is live in normal circumstances. IEC 61140
standard has renamed “protection against direct contact”
with the term “basic protection”. The former name is at least
kept for information.
Two measures of protection against direct contact hazards
are often required, since, in practice, the first measure may
not be infallible
6.2- INDIRECT CONTACT
An indirect contact refers to a person coming
into contact with an exposed-conductive-part
which is not normally alive, but has become
alive accidentally (due to insulation failure or
some other cause).
The fault current raise the exposed-conductive-
part to a voltage liable to be hazardous which
could be at the origin of a touch current through
a person coming into contact with this exposed-

conductive-part see. IEC 61140 standard has renamed “protection against indirect contact”
with the term “fault protection”. The former name is at least kept for information.
7- FIRST AID
The danger from an electrical shock depends on the type of current, how high the voltage is,
how the current travelled through the body, the person's overall health and how quickly the
person is treated.
 Call your local emergency number immediately if any of these signs or symptoms
occurs:
 Cardiac arrest
 Heart rhythm problems (arrhythmias)
 Respiratory failure
 Muscle pain and contractions
 Burns
 Seizures
 Numbness and tingling
 Unconsciousness
While waiting for medical help, follow these steps:
 Look first. Don't touch. The person may still be in contact with the electrical source.
Touching the person may pass the current through you.
 Turn off the source of electricity, if possible. If not, move the source away from you
and the person, using a dry, no-conducting object made of cardboard, plastic or
wood.
 Check for signs of circulation (breathing, coughing or movement). If absent, begin
cardiopulmonary resuscitation (CPR) immediately.
 Prevent shock. Lay the person down and, if possible, position the head slightly lower
than the trunk with the legs elevated.
After coming into contact with electricity, the person should see a doctor to check for internal
injuries, even if he or she has no obvious signs or symptoms.
Caution
 Don't touch the person with your bare hands if he or she is still in contact with the
electrical current.
 Don't get near high-voltage wires until the power is turned off. Stay at least 20 feet
away — farther if wires are jumping and sparking.
 Don't move a person with an electrical injury unless the person is in immediate
danger.

13
SAFETY PROCEDURE IN ELECTRICAL WORK (STANDARDS AND BEST
PRACTICES)
SAFETY PROCEDURE IN ELECTRICAL WORK (STANDARDS AND
BEST PRACTICES)

1- INTRODUCTION
The security in electrical work is one of the most important part of the work. By nature
electricity is dangerous and all actions have to be taken to prevent electric hazards and
protect people against Direct and Indirect chocks.
2- PREVENT DIRECT CONTACTS:
When it is not possible to shut down the power or lock a switch
disconnector, live accessible part to workers must be ensured
by:
- Remoteness,
- Obstacles
- Insulation.
2.1- REMOTENESS
Remoteness is to provide enough distance between live parts and worker that a contact
won’t be possible with conducting object. (metallic pipe, …)
2.2- OBSTACLES
The insulation between people and live part is
provided by putting in place obstacles when the
remoteness is not possible. The obstacles can be
cabinets, boxes … protecting people against direct
contact.
2.3- INSULATION
Insulation consist in cover live part with insulated
material such as insulated mat … This is required
when the remoteness and obstacle procedure can't be
put in place.

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PRACTICES)
3- PREVENT INDIRECT CONTACT
3.1- BY AUTOMATIC DISCONNECTION OF SUPPLY
This principle consist in connected to the earth all metallic part of
equipment and appliances. The disconnection can be done by
MCB or RCCD depending on the earthing system. Devices will
control and measure the current going through the earth. The
disconnection should be fastest as possible.
3.2- WITHOUT AUTOMATIC DISCONNECTION OF THE SUPPLY
This can be done by three ways:
- Class II equipment
- Isolated circuits
- Very low voltage
Voltage range from IEC
IEC voltage range AC DC Defining risk
High voltage (supply
system)
> 1000 Vrms > 1500 V electrical arcing
Low voltage (supply
system)
50–1000 Vrms 120–1500 V Electrical shock
Extra-low voltage
(supply system)
< 50 Vrms < 120 V Low risk
3.2.1-PROTECTION BY CLASS II EQUIPMENT
A class II equipment in addition of the main insulation has a double insulation.
3.2.2-PROTECTION BY ISOLATED CIRCUITS
The principle of this protection is by using transformer to isolate circuits. The second circuit is
completely isolated from the earth and from the power supply.
3.2.3-PROTECTION BY USING EXTRA-LOW VOLtAGE
The protection is ensured by the use of a voltage under 50 V in AC, voltage under this there
is no danger for people.
4- EQUIPMENT CLASSIFICATION
In the electrical appliance manufacturing industry, the following IEC protection classes are
used to differentiate between the protective-earth connection requirements of devices

4.1- CLASS 0
These appliances have no protective-earth connection and feature only a single level of
insulation and were intended for use in dry areas. A single fault could cause an electric shock
or other dangerous occurrence. Theses appliances are forbidden.
4.2- CLASS 1
These appliances must have their chassis connected to electrical earth (ground)
by a separate earth conductor (coloured green - green/yellow in most countries).
The earth connection is achieved with a 3-conductor mains cable, typically ending
with 3-prong AC connector which plugs into a corresponding AC outlet. The basic
requirement is that no single failure can result in dangerous voltage becoming exposed so
that it might cause an electric shock and that if a fault occurs the supply will be removed
automatically.
A fault in the appliance which causes a live conductor to contact the casing will cause a
current to flow in the earth conductor. If large enough, this current will trip an over-current
device (fuse or circuit breaker (CB)) and disconnect the supply.
4.3- CLASS 2
A Class II or double insulated electrical appliance is one which has been designed
in such a way that it does not require a safety connection to electrical earth
(ground). The basic requirement is that no single failure can result in dangerous
voltage becoming exposed so that it might cause an electric shock and that this is
achieved without relying on an earthed metal casing. This is usually achieved at least in part
by having two layers of insulating material surrounding live parts or by using reinforced
insulation.
4.4- CLASS 3
A Class III appliance is designed to be supplied from a separated/safety extra-low
voltage (SELV) power source. The voltage from a SELV supply is low enough that
under normal conditions a person can safely come into contact with it without risk of
electrical shock. For medical devices, compliance with Class III is not considered sufficient
protection, and further more-stringent regulations apply to such equipment.
5- IP CODE
The IP Code, International Protection Marking (IEC 60529), classifies and rates the degree of
protection provided against the intrusion (including body parts such as hands and fingers),
dust, accidental contact, and water by mechanical casings and electrical enclosures.
The standard aims to provide users more detailed information than vague marketing terms
such as waterproof. The digits (characteristic numerals) indicate conformity with the
conditions summarized in the tables below. Where there is no protection rating with regard to
one of the criteria, the digit is replaced with the letter X.
With the IP rating IP 54
- “5” describes the level of protection from solid objects

17
PRACTICES)
- “4” describes the level of protection from liquids.
6- IK CODE DEFINITION
Standard IEC 62262 defines an IK code that characterises the aptitude of equipment to resist
mechanical impacts on all sides.

7- OVERVOLTAGE CATEGORIES
Measurement category is classification of live electric circuits is used in measurement and
testing of installations and equipment, usually in the relation within a building (residential or
industrial).
The categories take into account the total continuous energy available at the given point of
circuit, and the occurrence of impulse voltages. The energy can be limited by circuit breakers
or fuses, and the impulse voltages by the nominal level of voltage
There are four categories designated by a mark such as “CAT III, 150 V" or "CAT IV, 1000
V".
 CAT I is applicable to instruments and equipment, which are not intended to be
connected to the mains supply. Because the available energy is very limited, this
category is normally not marked on the equipment.
Examples: low voltage electronic circuits, load circuits of bench power supplies, etc.
 CAT II defines circuits which are intended for direct connection into mains sockets or
similar points. The energy in such installations should be limited to below 100 A
continuously (or below 500 A for voltages not exceeding 150 V). The maximum
available continuous power must be limited (for instance by a circuit breaker) to not
more than 22 000 VA.
Example: a device connected to a 240 V mains socket with 13 A fuse (energy limited to 3100
VA)

19
PRACTICES)
 CAT III is for circuits which can be connected to the mains installation of a building.
Energy is limited by circuit breakers to less than 110 000 VA with the current not
exceeding 11 000 A.
Example: 110/240 V distribution boards, busbars, or equipment permanently connected to
the 3-phase power supply (e.g. electric motors).
 CAT IV includes circuits which are connected directly to the source of power for a
given building. There are very high levels of available energy (e.g. limited only by the
power transformer) and arc flash can occur.
Example: measurements on a cable connecting the power transformer and a building (i.e.
before the circuit breakers in the building).
In addition to the label “CAT”, the maximum voltage must be marked. This voltage is the
maximum voltage between live and ground of the circuit or the same overvoltage range.

Rated Voltage IEC 61010-1 2nd Edition
CAT IV CAT III CAT II
150V 4,000V 2,500V 1,500V
300V 6,000V 4,000V 2,500V
600V 8,000V 6,000V 4,000V
1,000V 12,000V 8,000V 6,000V
Resistance 2 ohms 2 ohms 12 ohms
8- SECURITY EQUIPMENT
“It is the duty of all persons who may be concerned with the installation, operation and
maintenance of electric lines and apparatus to make themselves thoroughly conversant with
the regulations and safety rules governing the work they may have to undertake on these
lines and apparatus.” (IS.5216.1.1.1982 § 2.1)
8.1- PERSONAL PROTECTIVE EQUIPMENT (PPE)
Personal protective equipment (PPE) is all equipment needed to
protect an electrician against electric shock to protect himself. Each
worker undertakes the responsibility of its protective equipment and
must check the condition on each equipment before use. Any
damaged equipment should be not used and be replaced.
The PPE are:
 safety glasses
 face shields
 hard insulated hats
 safety isolated shoes
 insulating (rubber) gloves with leather
protectors
 insulating sleeves
 flame-resistant (FR) clothing

21
PRACTICES)
8.2- INSULATING PROTECTIVE EQUIPMENT (IPE)
Insulating Protective Equipment (IPE) includes items such as:
 Insulating mat
 Insulating tools
 Insulating ladder
 Insulating pole
 Insulating tools
 voltage detector
 temporary-grounding and temporary-short-circuit set
 The voltage detector is used to verify the absence of voltage
on the part of the equipment which has been putting dead.
Before using it, it must be check to avoid malfunction.
 The temporary-grounding and temporary-short-circuit set
is used to connect all the dead conductors together and
connect them to the ground to prevent hazards. The
ground should be connected first and secondly short-
circuited.
8.3- COLLECTIVE PROTECTIVE EQUIPMENT
The collective protective equipment is all equipment used to mark and take away people to
avoid electric hazards by putting in place barrier, obstacle…
There are:
 Protective screen
 Poles, chains
 Warning board and sign

9- MEASURING DEVICES
Make an electrical measurement is one of the situations where the risk of electric shock is
important. The electrician should be sure that the measuring device is in good condition and
matches some rules.
The measuring device should:
 Have an insulating case
 Be Class II
 Have an IP2X
 Have the right measurement category.
All accessories have to match those rules.
10- PERMIT-TO-WORK SYSTEM
All work on major electrical installations shall be carried out under permit-to-work system
which is now well established, unless standing instructions are issued by the competent
authority to follow other procedures except in extenuating circumstances (saving life…) in
this case the action taken shall be reported to the person-in-charge. The permit-to-work
certificate from the person-in-charge of operation to the person-in-charge of the men
selected to carry out any particular work ensures that the portion of the installation where the
work is to be carried out is rendered -dead and safe for working. All work shall be carried out
under the personal supervision of a competent person. If more than one department is
working on the same apparatus, a permit-to- work should be issued to the person-in-charge
of each department.
No work shall be commenced on live mains unless it is specifically intended to be so done by
specially trained staff. In such cases all possible precautions shall be taken to ensure the
safety of the staff engaged for such work, and also of others who may be directly or indirectly
connected with the work. Such work shall only be carried out with proper equipment provided
for the purpose and, after taking necessary precautions, by specially trained and experienced
persons who are aware of the danger that exists when working on or near live mains or
apparatus.
 The permit is to be prepared in duplicate by the person-in-charge of operation on the
basis of message, duly logged, from the person-m-charge of the work.
 The original permit will be issued to the person-in-charge of work and the duplicate
will be retained in the permit book. For further allocation of work by the permit
receiving officer, tokens may be issued to the workers authorizing them individually to
carry out the prescribed work.
 On completion of the work, the original shall be returned to the issuing officer duly
discharged for cancellation.
11- EXAMPLE OF PERMIT-TO-WORK IN APPENDIX
Appendix 1

23
PRACTICES)
12- WORK ZONE AND VICINITY
The vicinity zone has been defined when a live part of an equipment is close to people. The
distance between them depends of the voltage. In lower voltage (50 – 1000 V AC) this
distance is 30 cm (11 in). It has also to be taken in account the possible movement of the
worker, movement of live part (aerial wire), tools…
It has been defined that the accessible live part are equipment with:
 In LV the IP is lower than IP2X
 In LV the IP is lower than IP3X
Work in a vicinity area requires the use of PPE and PEI.
 Zone 1: Non vicinity
 Zone 4: Vicinity area in LV (less than 30 cm from live parts). All equipment with IP <
IP2X is considered as live part.
 Zone 2: Vicinity area in HV (up to red line)
o 2 m (79 in) if U < 50 000 V (3 m -118 In – for aerial wire)
 Zone 3: This is the distance between the live part and the Minimum Distance
Approach (MDA). In this area there a risk of electric arc. The MDA distance is 60 cm
(24 in) up to 50 000 V. From 50 000 V the MDA is given by the following formula:
MDA(m) = 0,005 x U(kV) + 0,5

13- ELECTRICAL AUTHORIZATION
13.1- PREAMBLE:
The IEC 61010 defines the roles and duties to everyone involved in the electrical work. This
standard has been made to protect worker against electrical hazards.
13.2- PRINCIPLE:
People (electrician or not) give an authorization to do work related to electricity. This
authorization is given for particular task and certifies that the owner of the authorization
knows about risks and danger of electricity.
This authorization is required for:
 Enter in electrical room.
 Do electrical work. (Measurement, maintenance …)
 Manage electrical work
 Shut down power and lock switch-disconnector.
 Do electrical test
 Be a safety watcher
The employer is responsible to give the “Electrical Authorization”. He has to check that the
employee has the required knowledge on:
 Present electric hazards;
 Taking care of its own security and the security to people under its supervision;
 The action to do in case of accident
 The ability of the employee to do the work and tasks.
13.3- THE ELECTRICAL AUTHORIZATION
The Electrical Authorization is delivered by the employer to its selected employees under
its responsibility and it is only valid for the time of working to the company.
The Electrical Authorization is a document filed in by the employer and signed by the
employer and the employee.
13.4- WORK ZONE AND VICINITY
(As defined in the section 13.4-)
13.5- SYMBOLS AND CLASSIFICATION
The Electrical Authorization is defined by a letter, a number and a letter.
B x V
Who? What?
Where?
Second letter:
Type of work.
Number:
Function.
First letter:
Voltage level

25
PRACTICES)
13.5.1- FIRST LETTER
 B: Equipment or circuit in LV (50 – 1000 V AC) or VLV (<50 V AC)
 H: Equipment or circuit in HV (>1000 V AC)
13.5.2- NUMBER
 0: The holder doing only no electrical work or permitted Operation.
 1: The holder doing electrical work or Operation
 2: The holder in charge of electric work
13.5.3- SECOND LETTER
 R: The holder can do maintenances, connections, measurements, test.
 T: The holder can work under voltage.
 N: The holder can do Cleaning work under voltage
 V: The holder can work in vicinity.
 S: The holder can make connections and replacement.
 C: The holder can separate and lock a switch board and put equipment in dead
statute. He delivers the acknowledgment of lockout.
 E: The holder can perform test, verification, measurement and Operation.
 P: The holder can perform activities on solar panels.
13.5.4- ELECTRICAL AUTHORIZATION IN VICINITY (V)
The holder can perform in the vicinity of live part and under voltage. He has attended a
specific training.
13.5.5- ELECTRICAL AUTHORIZATION UNDER VOLTAGE (T)
The holder can perform work under voltage. He has attended a specific training and it is
delivered form limited company
13.5.6- ELECTRICAL AUTHORIZATION FOR CLEANING UNDER VOLTAGE
(N)
The holder manages and executes cleaning work on equipment under voltage. He has
attended a specific training.
All Electrical Authorization is given after the employee has attended to training.
13.5.7- RESPONSIBLE FOR ELECTRICAL OPERATION
It could be the employer and doesn’t need Electrical Authorization.
13.5.8- RESPONSIBLE OF SITE
He doesn’t need Electrical Authorization and he manages work, he can carry out non
electrical work.

13.6- WORK DEFINITION
13.6.1- NON ELECTRICIAN B0 / H0 OR H0V
The holder can access to the electrical room without supervision and execute or manage no
electrical tasks such as painting, cleaning…
13.6.2- EMPLOYEE IN CHARGE OF THE CLEANING UNDER VOLTAGE (N)
Employee managing or doing cleaning work under voltage.
13.6.3- ELECTRICIAN EXECUTANT B1 / H1 OR B1V / H1V
Employee that works as electrician and who is following instruction. He is aware of its
security.
 He can access to the electric room without authorization.
 He can perform work and Operation near live parts.
 He can perform measurement with clampmeter
 He is working in team under the supervision of the Responsible for electrical work
(B or H2) or Responsible of Intervention (BR)
 The holder of B1V or H1V can work in vicinity.
13.6.4- RESPONSIBLE IN CHARGE OF THE ELECTRIC WORK (B2 / H2 –
B2V / H2V)
The holder of the B2 or H2 manages the work and the tasks and takes all actions to ensure
its security and the security of people under its supervision.
 He is responsible of the execution of its security order.
 It can receive an acknowledgment of lockout and sign it
 The older is also 0 and 1
 The holder of B2V or H2V can work in vicinity.
13.6.5- RESPONSIBLE IN CHARGE OF THE LOCKOUT (BC / HC)
The holder of a BC is performing the Power disconnection of equipment by opening a switch
disconnector and locks it with proper lock. He takes all action to guaranty the safety and
security.
 He has to have the agreement from the Responsible of site
 He executes the four steps of the lockout or only the two first. In this case, the last
two steps are done by the Responsible in charge of the electric work.
 The BC or HC Electrical Authorisation doesn’t allow the holder to supervise the
security.
13.7- INTERVENTIONS
13.7.1- RESPONSIBLE IN CHARGE OF INTERVENTION (BR)
The holder can be assisted by an Electrician executant on equipment which has previously
been lockout.
 The Responsible in charge of Intervention (BR) is designated.

27
PRACTICES)
 He operates on small or medium equipment and to do short time maintenances. He
can work alone.
 He can search faults, check the operating system, do measurements, the lockout and
the unlockout for himself, change fuse, connection / disconnection with power.
13.7.2- RESPONSIBLE FOR CONNECTION AND REPLACEMENT (BS)
 The holder can change lamp or fuse,
 The holder can connect a circuit with a temporary one
 The holder can’t lockout – unlockout for himself
13.8- THE RESPONSIBLE OF OPERATION
 Test, measurement and verification are electrical task on VLV, LV and HV equipment.
 These tasks don’t require modifying the equipment but can require safety and security
measure.
 Operations include Exploitation, Emergency and Lockout.
13.8.1- SPECIFIC TASKS
13.8.1.1-Checking (BE – HE)
 Allow to work alone
 No current or section limitation
 The holder can’t lockout for himself.
 Verification of security devices correct operation, measurement of values (insulation,
earthing resistance…)
13.8.1.2-Test (BE – HE)
 Require to power the equipment but not the operation.
 The holder can have a part or all Responsible of site duties for the test part.
Electrical Authorization depending of the test:
 B2V test, H2V test (Works)
 BR (intervention)
 BE Test, HE Test (lab…)
13.8.1.3-Measurement (BE – HE)
 Can touch electrical measure or non-electrical measure
 In most of case, this is included in maintenance, checking and test.
13.8.1.4-Operation (BE – HE)
 Exploitation Operation
 Emergency Operation after a fire started.
13.9- ELECTRICAL AUTHORIZATION CERTIFICATE.
The certificate mentions the level of Electrical Authorization and it is signed by the employer
and the employee.

It should mention:
 Name, surname of the employee
 Function of the employee
 Employer
 Level (s) of Electrical Authorization
 date
13.10- THE PADLOCKING
This the duty of the holder of BC / HC Electrical Authorization
 He does or supervises the lockout
 He is responsible of the disconnection of the equipment from the power supply and
the lock of the switch disconnector.
 He his establishing the acknowledgment of lockout.
13.10.1- THE FIVE STEPS OF PADLOCKING
13.10.1.1- First step: Disconnection
Acknowledgment
should be signed
2- Lock
1-
Disconnect
3- Identify the
equipment 4- Doing the
Voltage checking
and the earthing
 Switch disconnector
 Sockets
 Withdraw fuse
 Plug devices
 Control, protesting devices

29
PRACTICES)
13.10.1.2- Second step: Equipment lock
13.10.1.3- Third step: identification
13.10.1.4- Fourth step: Voltage checking
The earthing and short circuiting are not mandatory in LV except:
 In case of induction voltage
 A risk of supply or with long cables.
13.10.1.5- Firth step: Mark working place
 Label and lock device
 On LV equipment, Board with
« Equipment lockout – Don not
Manoeuvre »
 Identify the place of the equipment
 Reading charts and circuit diagram
 Reading of labels and board
 Visual identification
 The voltage checking is carried out
close to the working place
 The earthing and short circuiting
should be done on both part of the
circuit.

14- APPENDIX
Appendix 1 : Permit-to-work
MODEL FORM OF PERMIT-TO-WORK
Name of the Organization ...................................................................................................
Department (issuing the permit) ............................................................................................
Permit No. .................... Time .....................................Date.................................................
1. I ....................................................................................... certify that the following
apparatus has been made dead, is isolated from all live conductors and has been
connected to earth and the work mentioned in para (3) can now be carried out in
accordance with the safety rules and regulations :
2. For the purpose of making the above apparatus dead, the following
switches/isolators/links/fuses have been opened and the section so isolated has been
earthed at each isolation point and danger notice plates tied thereon:
 Switches ....................................................................................................................
 Isolators .....................................................................................................................
 Links .........................................................................................................................
 Fuses .......................................................................................................................
3. Work to be carried out (testing work, if any, to be specifically mentioned):
..............................................................................................................................................
..............................................................................................................................................
..............................................................................................................................................
4. I have also recorded the above operations in the Log Sheet/Log Book including the
instructions for the person who may relieve me.
This permit is now being issued to ................................................................(name of the
person to whom the permit is being issued) for carrying out the work mentioned in para (3).
(Signature of the permit issuing authority)
(Designation) .........................................................

31
PRACTICES)
Department (receiving the permit) .........................................................................................
Permit No ...................... Time...................................... Date ...............................................
I ........................................................................................................................ confirm
that I have been issued this permit by................................................................ (name of
the permit issuing officer) and have been placed in direct and continuous charge of the
work mentioned in para (3) and accept the responsibility of carrying out the said work
taking all necessary safety precautions to avoid danger and no attempt will be made either
by me or by men working under my control to carry out any other work on any apparatus
other than that detailed in paras (1) and (3) on the reverse.
(Signature of the person receiving the permit and responsible for carrying out the above
work)
(Designation) ............................................................
I have transferred this permit to ............................................................................................ who will now
(Signature of the person transferring) (Signature of the person
receiving the permit)
the permit)
(Designation) ....................................... (Designation) ..............................
Time ...................................................... Date ..............................................................
I confirm that the work specified in para (3) on reverse has been completed and all
workmen withdrawn and warned that it is no longer safe to work on the apparatus
mentioned in para (1) on the reverse. I also confirm that all temporary earths and other
connections made by me and by men under my control have been removed except that
any precautionary steps taken by the permit issuing officer before the issue of this permit
have not been interfered with by me or by men under my control. I hereby return the permit
for cancellation leaving the dead apparatus ready for putting into service.
(Signature of the permit returning the permit)
(Designation) ...........................................................
Time ...................................................... Date ..............................................................
The work mentioned in para (3) on the reverse has been carried out; all earths made for
the purpose have been removed and danger notice plates put aside. The following
switches/isolators/links/fuses have been closed and apparatus put back into service. Entry
has been made in the Log Sheet/Log Book:
 Switches ....................................................................................................................
 Isolators ....................................................................................................................
 Links .........................................................................................................................
 Fuses .......................................................................................................................
(Signature of the permit cancelling authority)
(Designation) ...........................................................

33
PRACTICES)
Industrial Wiring
In this section the topics will be the different type of devices in industrial wiring.

DEVICES IN INDUSTRIAL WIRING

35
1- OBJECTIVE
 Drawing and electrical circuit according to the standards.
 Design an industrial electrical installation.
 Selecting and using devices
2- INTRODUCTION
The control of the industrial process is mainly powered by electricity. To carry out this,
electrical equipment have been designed with particular function. Whatever the load, the
voltage, the system AC or DC… an industrial wiring is setting up with basics function such as
Protection, switching, control…
3- MAIN BASIC FUNCTIONS OF THE EQUIPMENT FOR A MOTOR
STARTER SYSTEM
On most industrial equipment, there are 5 main functions: Disconnection, Breaking, Short-
circuit Protection, Overload Protection, and Switching. To ensure the protection of people
and equipment, all the equipment have to be placed in dedicated enclosure with the IP
according to the environment.
3.1- FUNCTION OF THE EQUIPMENT:
 Disconnection: To ensure the safety of people involved the installation maintenance,
the equipment or a part of the equipment must be disconnected from the power

supply. A padlocking mechanism may be added to the disconnection device to
procure more protection.
 Breaking: The breaking function is mandatory to be able to break the power supply
(on full load) in case of emergency.
 Short-circuit Protection: To avoid accidental damages on the equipment, disturbance
on the network (Unbalance), risk for the people security, the short circuit must be
detected and the faulty circuit have to be quickly opened.
 Overload Protection: Mechanical overloads and supply network faults are the most
common causes of the overload withstood by motors. This results in a considerable
increase in current drawn up by the motor, resulting in excessive temperature rise
and greatly reducing motor lifetime. It could even lead to destruction of the motor.
Motor overload must therefore be detected.
 Switching: Its function is to make and break the motor supply circuit.
4- DEVICES OR EQUIPMENT USED FOR THESE FUNCTIONS
Sizing and implementation of this equipment must comply with standards rules. A particular
attention is done on the discrimination and cascading of the protection and breaking.
5- DISCONNECTOR / SWITCH DISCONNECTOR / SWITCH FUSE
DISCONNECTOR
The use of disconnector is mandatory in industrial wiring. It is used
to isolate the electrical panel from the power supply.

37
 Disconnector: Its function is to disconnect and isolate an electrical installation (or a
part of electrical installation) to perform maintenance. It can be padlock. It has a small
interrupting capacity1
(IC). It will be open only if the load is stopped
(no current consumed)
 Switch-Disconnector: It has the same function as the disconnector
and in addition the switching function. It has a high IC and can open
circuits with load running.
 Switch-Fuse-Disconnector: It has the same function as the
switch-disconnector and in addition it carries fuses to protect the
equipment against short circuit. It has a high IC and can open
circuits with load running
The open position of a disconnector must be visible or indicated.
5.1- SYMBOLS:
Disconnector Switch Disconnector Switch Fuse Disconnector
1
IC : Interrupting Capacity : Capacity of contact to open a high current value without damages.
Control circuit
Power contacts
Power Fuses
Operatin
g handle

5.2- AM OR GG FUSES:
 gG Fuses protect against short circuit in an electrical installation, mainly for resistive
load.
 aM Fuses protect against short circuit in electrical installation with Inductive load such
as Induction engine or transformer.
5.3- TYPE OF FUSE:
Depending on the local standards, fuses can have different design.
NFC/Din Fuses type BS Fuses CC Fuses type J Fuse type
5.4- SELECTION CRITERIA
5.5- EXAMPLE
Find the reference of Switch Fuse Disconnector and the fuses to supply a Pa=10 kW
induction motor (cos 𝜌 = 0.851,) with a 3* 400V network and
𝑃𝑎 = √3 ∗ 𝑈 ∗ 𝐼 ∗ cos 𝜌
𝐼 =
𝑃𝑎
√3 ∗ 𝑈 ∗ cos𝜌
=
10 000
√3 ∗ 400 ∗ 0.851
= 16.98𝐴
• 1P + N: Phase + Neutral
• 2P: Two Phases
• 3P: Triphase
• 3P+N: Triphase + Neutral
No of
Poles
• Rated Voltage Ue; Maximum voltage between 2 poles.
Rated
Voltage
• Maximun curent that the device can support without any damages
Rating
• gG or aM depending of the load
Fuses Type
• 1 or 2 control contact
No of control
contact
• Type of Operatin Handle
• Clamping system
• Padlocking system
Accesories
Switch Fuse Disconnector
reference

39
6- MAGNETIC RELAY: PROTECTION AGAINST SHORT CIRCUIT
The magnetic relay is used to detect short-circuits.
The current of the load is going through a coil. If
there is no SC, the current is too week to create a
magnetic field. If there is a SC, the current create a
high magnetic field with attract a lever to open
control contact. This contact will open the control
circuit and switch of the system.
6.1- SYMBOL:
7- THERMAL RELAY: PROTECTION AGAINST OVERLOAD.
As the magnetic relay, the thermal relay is used to protect the equipment against damages
due to an overload.
It contains three bimetal strips together with a trip
mechanism in a housing made of insulating
material. The bimetal strips are heated by the
motor current, causing them to bend and activating
the trip mechanism after a certain travel which
depends on the current-setting of the relay.

The release mechanism actuates an auxiliary switch that breaks the coil circuit of the motor
contactor (Figure 1). A switching position indicator signals the condition “tripped”.
 A = Indirectly heated bimetal strips
 B = Trip slide
 C = Trip lever
 D = Contact lever
 E = Compensation bimetal strip
7.1- SYMBOL:
Power circuit: Control circuit or
7.2- CLASS OF THE THERMAL RELAY:
The class of thermal relay define its behaviour in case of overload and the tripping time.

41
7.3- CHOICE OF THERMAL
RELAY:
The thermal relay is chosen
depending on the class and the rated
current of the load to be protected.
The thermal relay doesn’t open the
power circuit, it detect the overload
and through its control contact act on
the control circuit to switch off the
equipment in fault.
7.4- EXAMPLE:
A thermal relay protects an Induction motor with the following specifications: Pa=15
kW,cos 𝜌 = 0.8 power supply 3*400V, control circuit voltage 24V ac. Chose the thermal relay.
It would be Class 10A
• 2P: Two Phases
• 3P: Triphase
No of
Poles
• The class is defined
depending on the tripping
time at 7.2 times the rating
current.
Class
Thermal relay

𝐼 =
𝑃𝑎
√3 ∗ 𝑈 ∗ cos 𝜌
=
15 000
√3 ∗ 400 ∗ 0.8
= 27𝐴
Thermal relay: LRD 32, setting at 27 A
8- CIRCUIT BREAKER
A circuit breaker is an automatically operated electrical switch designed to protect an
electrical circuit from damage caused by Overcurrent/overload or short circuit. Its basic
function is to interrupt current flow after Protective relays detect faults condition. Unlike a
fuse, which operates once and then must be replaced, a circuit breaker can be reset (either
manually or automatically) to resume normal operation. Circuit breakers are made in varying
sizes, from small devices that protect an individual household appliance up to large
switchgear designed to protect high voltage circuits feeding an entire city. (Wikipedia)
As per the nature of the current, especially in case of short circuit, the circuit breaker has the
ability to cut electric arc. For this, different methods are used:

43
Low-voltage MCB (Miniature Circuit Breaker) uses air alone to extinguish the arc. These
circuit breakers contain so-called arc chutes, a stack of mutually insulated parallel metal
plates which divide and cool the arc. By splitting the arc into smaller arcs the arc is cooled
down while the arc voltage is increased and serves as additional impedance which limits the
current through the circuit breaker. The current-carrying parts near the contacts provide easy
deflection of the arc into the arc chutes by a magnetic force of a current path, although
magnetic blowout coils or permanent magnets could also deflect the arc into the arc chute
(used on circuit breakers for higher ratings). The number of plates in the arc chute is
dependent on the short-circuit rating and nominal voltage of the circuit breaker.
In larger ratings, oil circuit breakers rely upon vaporization of some of the oil to blast a jet of
oil through the arc.
Gas (usually sulphur hexafluoride) circuit breakers sometimes stretch the arc
using a magnetic field, and then rely upon the dielectric strength of the sulphur
hexafluoride (SF6) to quench the stretched arc.
Vacuum circuit breakers have minimal arcing (as there is nothing to ionize
other than the contact material), so the arc quenches when it is stretched a
very small amount (less than 2–3 mm (0.079–0.118 in)). Vacuum circuit
breakers are frequently used in modern medium-voltage switchgear to 38,000
volts.
Air circuit breakers may use compressed air to blow out the arc, or alternatively, the contacts
are rapidly swung into a small sealed chamber, the escaping of the displaced air thus
blowing out the arc.
Circuit breakers are usually able to terminate all current very
quickly: typically the arc is extinguished between 30 ms and 150
ms after the mechanism has been tripped, depending upon age
and construction of the device. The maximum current value and
let-through energy determine the quality of the circuit breakers.
(Wikipedia)
8.1- CURRENT RATING:
Circuit breakers are manufactured in standard sizes. Miniature circuit breakers have a fixed
trip setting. Larger circuit breakers can have adjustable trip settings
International Standard--- IEC 60898-1 and European Standard EN 60898-1 define the
rated current In of a circuit breaker for low voltage distribution applications as the maximum
current that the breaker is designed to carry continuously (at an ambient air temperature of
30 °C). The commonly-available preferred values for the rated current are 6 A, 10 A, 13 A, 16
A, 20 A, 25 A, 32 A, 40 A, 50 A, 63 A, 80 A, 100 A and 125 A (similar to the R10 Renard
series, but using 6, 13, and 32 instead of 6.3, 12.5, and 31.5 – it includes the 13A current
limit of British BS 1363 sockets). The circuit breaker is labelled with the rated current in
amperes, but without the unit symbol "A". Instead, the ampere figure is preceded by a letter
"B", "C" or "D", which indicates the instantaneous tripping current — that is, the minimum

value of current that causes the circuit breaker to trip without intentional time delay (i.e., in
less than 100 ms), expressed in terms of In:
9- THE CONTACTOR
A contactor is an electrically controlled switch used for switching an electrical power circuit,
similar to a relay except with higher current ratings. A contactor is controlled by a circuit
which has a much lower power level than the switched circuit.
A contactor is composed on two parts: Power and control part.
The power part is composed of contacts (3 / 4) with high Interruption capacity. All contact are
closing or Opening at the same time. They are moved by the coil of the control circuit. When
this one is supplied, it attracts the moving part and the power contacts are closing. In
contrary, when the coil is not powered, a spring move back the moving part and the power
contacts are opening. A contactor is a switch controlled by a coil.
The power part can have 1, 2, 3 or 4 contacts. They can be Normally Open or Normally
Closed. The rating depends on the load current.
Power part
Control part Auxiliary contacts

45
The control is divided in two parts: The coil, which can be supplied in ac or dc and several
voltages and the auxiliary contact moving at the same time of the power contacts.
If it is require, auxiliary contact can be added on the contactor’s front or side.
9.1- CONTACTOR CHOICE:
9.2- CATEGORIES:
The IEC 947-4 Standard characterises the various category of use of the device control. For
the motor feeder in ac, the mains categories are:
• 2P: Two Phases
• 3P: Triphase
No of
Poles
• Categories of use define the value of the rating current wich the contactor soulld
establish or cut.
• it depends on the load caracterisitc and the opening and closing conditions.
Categories
of use
• Ie: is defined according to the voltage rating, the frequency, the service, the
category.
Rating
• Ue: maximum voltage between poles
Voltage rating
• Standarzied Power of the load
Power
• Uc: Value of the control circuit voltage, voltage of the
coil.
Control circuit voltage
• Additional contacts, delay, locking system.
Accessories

9.3- SYMBOLS:

47
INDUSTRIAL ELECTRICAL DIAGRAM

1- INTRODUCTION
Electrical diagram is the part of the industrial system. It is one of the first steps in the design
process of an industrial system or machine. It is not an architectural representation (in
industrial), it shows the devices used in the system and the connections between them.
Symbols used have been designed and standardized to be readable by
every technician.
2- SYMBOLS USED
There are plenty of symbols representing an electrical device. To be able
to be read by every technician, symbols were standardized and an
international standard created: The IEC IEC60617 – part 7. Local
standards have been designed by following the IEC one.
The IEC 60617 is available on annexe files. (IEC60617 Symbols.pdf)
The target of the electrical diagram is the readability of the operation of
the different circuits (Control, Power … circuits)
2.1- SYMBOLIZATION OF DEVICES
 Main contacts: Power circuit
o From 0 (control device) to 4 power contacts.
o Always represented together, they are drawn in solid line
 Auxiliary contacts: Control circuit
o From 0 to 5 contacts, more with the use of add
o Ungrouped, drawn in fine line
o 2 types: Normally Open (NO), Normally Closed (NC)
o Mechanically linked to the control part they indicate the state of the device. By
this, the state of a device can be used in a control circuit.
 Control part (control of the contacts) Operated by Pushing
o Manual: drawn on the contact’s left side.
o Electric (coil) load of the control circuit
 Mechanical link:
o Partially drawn if it disturbs the reading of the electrical diagram.
Power part
Control part
Mechanical link
Auxiliary contacts

49
2.2- IDENTIFICATION OF THE DEVICE TERMINALS
 Power contact:
o Single or double poles device: Identification mark => 1 – 2, 3 – 4.
o Three poles or tetrapolar device: Double identification mark => 1/L1 – 2/T1; …
 Control contacts:
o The units digit designate the function of the contact:
 Normal – NC => 1 – 2
 Normal – NO => 3 – 4
 Special (thermal, delayed, etc.) – NC => 5 – 6
 Special (thermal, delayed, etc.) – NO => 7 – 8
o The tens digit designate only for the multi-contacts device by
design the order of the contact. E.g. 13 – 14 => fist contact
(NO) of the device, 21 – 22 => second contact (NC) of the
device…
 Control part:
o Coil: A1 – A2
o Pilot Lamp: X1 – X2
 Terminal board: X (Si terminal board). (Si
terminal)
 Terminal board: X (Si terminal board). (Si
terminal)
2.3- EQUIPOTENTIAL IDENTIFICATION OF WIRES:
 Rules:
o Unique number for all conductors with the same potential
o Incrementation (+1) on each device on the reading direction (left to right / top
to bottom)
o Power circuit: number preceded by the type of conductor (L, N, PE)
2.4- CROSS REFERENCE UNBUNDLED SYMBOLS
 The location of the equipment is given by the coordinates on the folio frame.
o E.g. 02 – G5 => Folio 02 – Column G, Row 5
 Below the master symbol, list of the slave symbols
 On the slave right symbol, the references of the master symbol.

51
INDUSTRIAL WIRING - WIRING RULES

1- OBJECTIVE
 Drawing and electrical circuit according to the standards.
 Understanding wiring procedure
2- HARDWARE LOCATION:
To implement the devices on a mesh in cabinet, it is recommended following the rules
hereafter:
2.1- SPACE BETWEEN
DEVICES:
 Wiring by using raceway: leave
4 to 6 cm between the devices
and the raceway.
 Wiring in strand: Leave 4 to 6
cm between devices
2.2- COMMON
FUNCTIONS:
 it is recommended to place
side to side the equipment with
common function e.g.
contactor forward / reverse,
contactor going up / down…
 The rating plate of the contactor coil should be accessible for reading.
3- WIRE COLOUR:
For the power circuit the following colour should be used:
 Phase 1: Brawn (red)
 Phase 2: Black (Yellow)
 Phase3: Grey (Black)
 Neutral: Blue
 Earthing: Yellow /green
Note that the phases can be wired with one colour; in this case, the marking is mandatory.
The control circuit will be wired in grey. Other colour can be used but the marking is
mandatory.

53
4- CONNECTION OF EQUIPMENT
4.1- CONTACT:
 The input must be on the top or left of the devices, the output on the bottom or right.
4.2- CONTROL BOX:
 Input on the left, output on the right
4.3- COILS:
 Input – A1, output – A2
5- CONNEXION:
The size of the wire depends on the current that it will carry. Usually, the cross section of the
wire is 0.75 mm2
for the control circuit and 1.5 mm2
for the Power circuit. The size should be
adapted to the current.
Cross section (mm2
) 0.5 0.75 1.0 1.5 2.5 4 6 10 16
Current max( A) 3 6 10 16 25 30 40 60 80
5.1- PREPARATION OF THE WIRES:
 Set up the stripping plier to prevent to cut the wire or strands.
 Remove the right length of insulation.
 Slight twist of the strand wires.
 The wire ends should have lugs to procure a good connection. The
ferrule is clamped with dedicated tools. If the terminal is a spring type,
lugs are not required.
 Prevent to put strand outside the connector.
5.2- CONNEXION TO TERMINAL
The position of the wire is important. The wire must be place according to the tightening
direction of the connector:
Tightening
direction
Tightening
direction
Tightening
direction
Tightening
direction

 If there is two wire, place them on both sides of the terminal
 Note that two wire maximum must be connected to one terminal.
5.3- WIRING RULES:
Regarding the wiring in raceway, the following rules must be followed:
 Wire the power circuit before the control circuit.
 For the control circuit: wire first the coil return (A2 terminals) then the button box, then
the cabinet door and finally the mesh.
 The bridge between two terminals should be run
through the raceway.
 The length of the wire should be enough to
shape it.
 Wire must come perpendicularly to the device or
terminal
 Wire terminal block from left to right and from
top to bottom.
 For a comb wiring, wire must be parallel
 The link to the loads, sensors should be made by cables.
 The identification of the wire is given by the equipotential number on the diagram.
This identification can be letters, numbers or both. The identification is made with
ring, clips or direct printing.
 All devices should be marked with specific tag.
 Check the tightening.
5.4- WIRING PROCEDURE
 Check with Multimeter the state of the contact

55
 Wiring the horizontal connection then each load.
 Mark each wire when it is out in place. Reading from bottom to top or left to right.
 Identification must be at 5 to 10 mm from the terminal.
 Tick on the diagram the wire put in place.
6- ELECTRICAL FILE
At the end of the wiring, an electrical file must be provided. It contents:
 List of the folios
(numbered: ( no
folio)/(total no of folio);
 Developed diagram
 List of equipment
(nomenclature)
 Cable list and connexion
The electrical file should be stored inside the cabinet.
7- EXAMPLE
7.1- SAMPLE DIAGRAM:

7.2- REAL WIRING DIAGRAM

57
CONDUCTORS AND CABLES

1- OBJECTIVE
 Select the equipment in order to design an electrical circuit
2- CONDUCTORS AND CABLES:
They are the active part of the electrical links. Their duty is to carry the electrical
current. There is a large range of conductor and cable.
- An insulated conductor is an association between a conductor and insulation
- A single core cable is an Insulated conductor with one or more protective sheath.
- A cable is a bundle of conductors electrically insulated sharing the protective sheath.
3- GENERAL STRUCTURE.
A conductor or Cable is made with two essentials parts; each has its own function
(conductive or insulating)
3.1- CONDUCTIVE PART.
3.1.1-ELECTRICAL FEATURES.
Conductor
Insulation
Protective sheath
Insulation
Conductor
Protective sheath
Conductor
Insulation

59
The conductor's role is to conduct current, it must have a resistivity (ρ) very low to limit (for
neglected) losses by Joules effect
R = (* l)/S
The cross section depends on the
current in the conductor. The cross
section standards are from 0.6 to 360
mm2
(J is the density of current in
A/mm2
)
I = J * S
3.1.2-MECHANICAL FEATURE.
The conductor should be enough flexible to follow the complicated path of the conduits.
There are:
Multi strand conductors are made with several twisted strands. The strands are put in several
layers.
- 1st
layer = 1 + 6 = 7 strands
- 2nd
layer = 1 + 6 + 12 = 19 strands
 - 3rd
layer = 1 + 6 + 12 + 18 = 37 strands
The single strand conductor has one strand and the cross section can be up to 35 mm².
The flexibility of a cable depends of the number of strand for the same conductive cross
section. The flexibility is defined in 6 classes. Class 1: less flexible, class 6 more flexible. We
usually use classes 1, 2, 5, 6.
Standards
- Cables for fixed installations:Classes 1 and 2
- The flexibles: Classes 5 and 6
- Copper welding cables: Class 6
Copper Aluminium
Resistivity 1.72 * 10-8
Ω.m 2.78 * 10-8
Ω.m
Density 8.9 2.7
Price Expensive Good price
Use
ULV, LV
Local network
and
Underground
HV and UHV
Aerial network

Class 1 Class 2 Class 3 Class 4 Class 5 Class 6
médiocre
Poor
Solid
Conductor
Passable
Passable
Bon
good
Tres bon
Very good
Excellent
Excellent
Exceptionnel
Exceptional
Extra-flexible
3.2- INSULATION PART: (DIELECTRIC)
Insulation performs the insulation between conductors with different voltages and the ground
or the earth. The insulation should have a very high resistivity.
Currently, synthetic plastics have replaced insulator like paper, natural rubber. The main
insulation is made with:
- Polyvinyl chloride (PVC) or polyethylene (PE)
- Chemically cross-linked polyethylene (PRC)
Insulations used are characterized for their rated voltage isolation. The nominal voltage of
the cable must be at least equal to the nominal voltage of the installation (different voltages
250V, 300V, 500V, 750V, 1000V).
Cross
section
Conductors Cross
section
Conductors
mm² Class 1 Class 2 Class 3 mm² Class 4 Class 5 Class 6
1.5
2.5
4
6
10
16
25
35
50
70
95
120
150
185
240
300
400
500
630
800
1 000
1 x 1.38
1 x 1.78
1 x 2.25
1 x 2.76
1 x 3.57
1 x 4.50
1 x 5.65
1 x 6.60
7 x 2.93
19 x 2.85
19 x 3.20
37 x 2.85
37 x 3.20
7 x 0.50
7 x 0.67
7 x 0.85
7 x 1.04
7 x 1.35
7 x 1.70
7 x 2.14
7 x 2.52
19 x 1.78
19 x 2.14
19 x 2.52
37 x 2.03
37 x 2.25
37 x 2.52
61 x 2.25
61 x 2.52
61 x 2.85
61 x 3.20
127 x 2.52
127 x 2.85
127 x 3.20
12 x 1.04
19 x 1.04
19 x 1.35
16 x 1.53
27 x 1.53
37 x 1.57
37 x 1.78
61 x 1.60
61 x 1.78
91 x 1.60
0.5
0.75
1
1.5
2.5
4
6
10
16
25
35
50
70
95
120
150
185
240
300
400
500
7 x 0.30
11 x 0.30
14 x 0.30
12 x 0.40
20 x 0.40
20 x 0.50
30 x 0.50
49 x 0.50
56 x 0.60
84 x 0.60
98 x 0.67
144 x 0.67
192 x 0.67
266 x 0.67
342 x 0.67
266 x 0.85
330 x 0.85
420 x 0.85
518 x 0.85
672 x 0.85
854 x 0.85
16 x 0.20
24 x 0.20
32 x 0.20
30 x 0.25
50 x 0.25
56 x 0.30
84 x 0.30
80 x 0.40
126 x 0.40
196 x 0.40
276 x 0.40
396 x 0.40
360 x 0.50
475 x 0.50
608 x 0.50
756 x 0.50
925 x 0.50
1221 x 0.50
1525 x 0.50
2013 x 0.50
1769 x 0.60
28 x 0.15
42 x 0.15
56 x 0.15
85 x 0.15
140 x 0.15
228 x 0.15
189 x 0.20
324 x 0.20
513 x 0.20
783 x 0.20
1107 x 0.20
702 x 0.30
909 x 0.30
1332 x 0.30
1702 x 0.30
2109 x 0.30
2590 x 0.30
3360 x 0.30
4270 x 0.30

61
Group Name Use Example Price
Synthesis Polyvinyl Chloride (PVC)
Cross-linked polyethylene
(XLPE)
Polytetrafluoroethylene
(PTFE)
Kapton
Butyl rubber (PRC)
Silicon
General use
General use
High
Temperatures
High Voltage
Flexibility
required
High
Temperatures
Building
Electronic
Electronic
Electronic
Vacuum
cleaner
Halogen
Cheap
Cheap
Expensive
Very
expensive
Cheap
Expensive
Mineral Mica HV Winding HV
Transformer
Expensive
Vegetal Cotton Taping Lighting Expensive
Gas Air Bush-Bar or
Aerial
Aerial lines Free
3.3- PROTECTIVE SHEATH.
The protective sheath must meet conditions related to the cable environment, such as:
- The temperature;
- The presence of water, dust;
- The possibility of mechanical shocks, etc ....
The mechanical properties of the insulation part are not always sufficient to protect the cable
from external influences. To correct this, the insulation is covering with a protective sheath
which must have characteristics like:
- Mechanical (tensile strength, torsional bending, shock);
- Physical (resistance to heat, cold, moisture, fire);
- Chemical (corrosion resistance, aging).
Underground cables: An underground cable essentially consists of one or more conductors
covered with suitable insulation and surrounded by a protecting cover.
Is used as cladding materials or insulating materials such as PVC and CBP, or metallic
materials such as lead, aluminium, steel strip.
Conductor
PE insulation
Plastic
Lead
Paper
Polyvinyl
chloride (PVC)
Steel layer

4- CONSTRUCTION OF CABLES:
The various parts of underground cables are as under as shown in the picture.
4.1- LV CABLE
4.2- HV CABLE
5- NUMBER OF WIRE IN A PIPE:
Whatever the conduit is, the cross section of wire should always be less than 1/3 of the cross
internal section of the conduct:

63
n s
S
3
. 
o n : Nb of wire
o s : Cross section of wire including insulation
o S : Internal cross section of the conduit
Yes NO
6- INSTALLATION METHODS.
6.1- IDENTIFICATION OF INSTALLATION METHODS.
The Installation method is the how a conduit is put in place (aerial, surface mounting, flush
mounting…). The installation method influences the cooling quality of the wires. It is very
important to identify the installation method before select the cross section of the wires.
7- COLOURS IN SINGLE PHASE.
Phas
e
Phas
e
Protective Earth
Neutral
Neutral
Red
Black
Blue
Yellow/Gr
een

8- COLOURS IN THREE PHASES
Phas
e
Neutral
Neutral
Phas
e
Phas
e
Phas
e
Phas
e
Phas
e
Phas
e
Phas
e
Phas
e
Phas
e
Phas
e
Phas
e
Protective
Earth
Protective
earth
Grey
Yellow/Green
Brawn
Black
Black
Brawn
Grey
Grey
Black
Brawn
Blue
Grey
Black
Brawn
Blue
Yellow/Green

65
ENGINE CHOICE
ENGINE CHOICE

1- OBJECTIVE
2- DEFINITION
Electric converters : Electrical machines
We define an electrical machine as a converter Mechanical to Electrical or Electrical
to mechanical.
Electrical to Machanical => Motors Mechanical to Electrical => Generator
2.1- CHOOSE OF AN ELECTRICAL MACHINE:
The choice of an electrical machine depends on the inputs an doutput energies
Electrical :
 The network ;
 The characteristics ;
 …
Mechanical :
 The torque ;
 The speed (rotation or linear) ;
 The Power …
In addition to these fundamental characteristics for the choice of an electric machine, other
criteria must nevertheless be taken into account.
Among others:
 The environment (definition of the IP, the IK, the temperature class, the altitude of
operation, nature of the atmosphere ....)
 Operating service;
 The dimensions of the machine (shaft height, ...);
 The operating position (Vertical, Horizontal);
Examples of Electromechanical converter:
 DC machine (Motor or Dynamo);
 Asynchronous machine (Engine or Generator);
 Synchronous machine (Engine or Alternator);
 Special machines (2-speed asynchronous motor, stepper motor, linear motor ...)
Motor
Convert
Energy
Electric
Mechanic
Mechanic
Electric
Generator

67
ENGINE CHOICE
2.2- OPERATING POINT:
MOTOR operation: This is the point where the couple '”voltage – current” allows the
operation of the machine for a particular couple “Speed – torque”.
GENERATOR mode: This is the point where the couple “Speed – Torque” allows the
machine to operate for a particular “Voltage – Current” Couple.
IN ALL CASES, IT IS THE LOAD THAT IMPOSES THE OPERATING POINT OF AN
ELECTRIC MACHINE (except in special cases).
2.3- NOMINAL POINT OF OPERATION:
This is the operating point of the machine where the energy efficiency is maximum. Efficiency
is defined as the ratio of outgoing power to incoming power.
2.4- CONCEPT OF LOAD:
For a motor, it is called load, the mechanical device which imposes the couple of
characteristics “Speed – Torque”. (exp For an elevator, it is the speed of displacement which
imposes the frequency of rotation, and the mass to move which impose the torque).
For a generator, the electrical device that imposes the pair of characteristics “Voltage –
Current” is called a load. (The lighting of a bicycle headlamp is imposed by the voltage at
these terminals. For constant lighting, it is necessary to drive at a constant speed).
3- CRITERIA FOR ELECTRICAL CHOICE:
3.1- NETWORK :
 alternating single-phase, three-phase with or without neutral, multiphase ...
 Direct Current ;
3.2- ELECTRICAL CHARACTERISTICS
 Voltage ;
 Frequency ;
 Power ;
4- CRITERIA OF MECHANICAL CHOICES:
The choice of a converter depends essentially on the type of load: torque, speed,
acceleration, operating cycle.

4.1- TRANSMISSION CHAIN :
Network
Power circuit Motor K load
Motor
Axel
Pa m
Pu
Tm
m
K=r/m
r
Pc
c
Tc
J
 Pa : Absorb power in W or KW ;
 m : Efficiency (m= Pu / Pa) ;
 Pu : Output power W ou kW (Pu = Tm m) ;
 Tm : Torque Nm ;
 m : Motor speed rad/s ;
 K : Speed reducing ratio (K = r / m ) ;
 r : Reduction gear’s efficiency (r = Pc/ Pu ) ;
 Pc : Power required in W ou kW ;
 c : Load speed in rad/s ;
 Tc : Resisting torque in Nm ;
 J : Moment of Inertia in kg/m2
;
We have to use the laws of mechanics to determine the parameters PU, m, Tm.
4.2- TYPE OF RESISTING TORQUE
The characteristic of the resistive torque as a function
of the speed defines the needs of the driven machine.
When this characteristic is not known, it is assimilated to
one of the three characteristics below.
4.2.1-PUMPING(1 AND 2):
The resistant torque Tr is quite strong at takeoff. It can be constant or grow slightly with
speed.

 .
k
Tr Cte
Tr 
Examples: Horizontal conveyor belt, lifting, Turbocharger.

69
ENGINE CHOICE
4.2.2- VENTILATION (3) :
The resistant torque Tr is quite weak at starting. It increases with the speed according to a
law :
2
'.
 k
Tr
Examples: Centrifugal pump, Fan.
4.2.3-SPIN (4) :
The resistant torque Tr is high at starting, it decreases with speed.


'
'
k
Tr , The power P is
constant.
Example: spinner, breaker.
4.3- THE MOMENT OF INERTIA:
Inertia characterizes moving masses (dynamic parameter). It is by its inertia that a system
opposes the changes of speed that we want to impose. The physical quantity associated with
inertia is the moment of inertia J en kg/m2
4.4- STUDY OF DYNAMICS:
4.4.1-FUNDAMENTAL EQUATION:
 Tm : Engine couple;
 Ta : Accelerator torque;
 Tr : Resistant torque opposed by the
load;
 J : Moment of inertia;
4.4.2- STARTING CONDITIONS:
The machine can only start if the starting torque of the machine is greater than the
load torque of the load.
r
a
m T
T
T 
 and
dt
d
J
Ta

 .

 Examples :
The engine starts Td > TR0 The engine doesn’t start Td < TR0
The acceleration is higher as : Tm is bigger tahn Tr and J is small.
4.4.3-RUNING AT OPERATING POINT):
n steady state the speed is constant. So the acceleration torque no longer exists.
4.4.4-STABLE OPERATION OF THE MACHINE:
 The stable operating point of the machine is the point
where the motor and resistive torque are equal.
 Note:
The motor is generally chosen so that the operating point
A is as close as possible to the operation in nominal mode.
T (Nm)
Tm = f ()
 (rad s-1)
Td
Tr = f ()
TR0
T (Nm)
Tm = f ()
 (rad s-1)
Td
Tr = f ()
TR0
T (Nm)
Tm = f (V)
 (rad s-1)
T
Tr = f ()

A
m
d T
T  => r
m
a T
T
dt
d
J
T 


 .
Si cte

 => 0


dt
d
=> r
m T
T 

71
ENGINE CHOICE
4.4.5-NATURAL SLOWDOWN OF THE MACHINE:
 The natural slowdown of the machine is obtained by
stopping the power supply of the engine at time t0.
 Note :
o Stopping the machine is shorter as the moment
of inertia is low.À t = t0 0

 a
r T
T => a
r T
T 
 =>
J
T
dt
d r



o The acceleration is negative therefore slowing down the machine.
4.4.6-BRAKING THE ENGINE:
 To achieve a braking it is added at time t0, a
braking torque Tf.
À t = t0 => 0


 f
a
r T
T
T => a
f
r T
T
T 


=>
 
J
T
T
dt
d f
r 



The braking torque can be produced by:
 A mechanical element;
 An external electrical system (powder brake, eddy current brake);
 By the engine itself:
 By DC injection;
 Generator operation.
In case of mains failure, only the mechanical brake ensures the immobilisation of the load.
t (s)
J important
 (rad s-1)
J faible
t0
t (s)
J important
 (rad s-1)
J faible
t0

5- OPERATING QUADRANTS OF A MACHINE:
The working Quadrant are :
 Motor : Q1 and Q3 (the engin provide a mechanic power)
 Generator or Break; Q2 and Q4 (The engine is absorbing a mechanic power)
Direction Speed Torque Power Quadrant Work Load
Direction 1 +
+
+
-
+
-
1
2
Motor
Generator
Resistive
Leading
Direction 2 -
-
-
+
+
-
3
4
Motor
Generator
Resistive
Leading
6- OTHER CRITERIA FOR CHOOSING AN ELECTROMECHANICAL
CONVERTER:
6.1- CHOICE BASED ON THE ENVIRONMENT:
6.1.1-DECOMMISSIONING:
The normal conditions of use of standard machines are: a temperature between -16 ° C and
40 ° C; the altitude below 1000 m.
Corrections must be made outside these values.
𝑃𝑡𝑜 𝑖𝑛𝑠𝑡𝑎𝑙𝑙 = 𝑃𝐶𝑎𝑙𝑐𝑢𝑙𝑎𝑡𝑒𝑑 ∗
𝑃1
𝑃

73
ENGINE CHOICE
6.1.2-IP :
It must be ensured that the chosen
machine will be protected against the insertion
of foreign material as well as against splashing
water. It is necessary that the IP of the machine
is higher digit by digit to the IP of the local or
the cabinet.
6.1.3-IK :
As with the IP, it must be ensured that the
machine will be able to withstand any shocks
that may occur during normal operation.
6.1.4-CLASS OF T° :
The main component for electric motor is a stator. What is stator? Basically stators are
wound with insulated windings made from cooper wire. The insulation materials for winding
of stator are such as polyester, poly vinyl formal, polyurethane etc.
The main purpose of insulation is to protect the windings in the slots of the stator lamination
and layer between winding coils. The insulation class is durability factor depend on whole of
insulation condition.
According from IEEE regulation, the classification of insulation electric motor has a deference
rating for maximum temperature that insulation winding can operate. We can see the
insulation class at motor nameplate. Please refer the table below for insulation class rating
temperature.

The windings of a machine are coated with a varnish that
deteriorates with high temperatures. The standard has defined
temperature isolation classes that ensure proper operation for at
least 105
hours.
In the case where the machine used would work with a temperature higher than that of its
class, it is necessary to correct the life of the machine using the table of thermal aging of the
insulators.
For an ambient temperature> 40 ° C, the machine is downgraded according to the following
coefficients:
𝑃𝑡𝑜 𝐼𝑛𝑠𝑡𝑎𝑙𝑙 = 𝑘 ∗ 𝑃𝑐𝑎𝑙𝑐𝑢𝑙𝑎𝑡𝑒𝑑
6.2- DUTY TYPES:
The choice of a machine is also conditioned by its operating conditions. Thus we define 8
"services" or Duty Types according to the operating conditions ('Start, Nominal operation,
idle operation, braking, stop).
In compliance with the classification of Std. IEC 60034-1 here are some indications regarding
the duty types which are typically considered as reference to indicate the rating of the motor.
 Continuous running duty (type S1)
 Short-time duty (type S2)
 Periodic duty (type S3-S8)
o Intermittent periodic duty (Type S3)
o Intermittent periodic duty with starting (Type S4)
o Intermittent periodic duty with electric braking (Type S5)
o Continuous-operation periodic duty (Type S6)
o Continuous-operation periodic duty with electric braking (Type S7)
o Continuous-operation periodic duty with related load / speed (Type S8)
 Non-periodic duty (type S9)
 Duty with discrete constant loads (and speeds) – type S10
i k
45 °C 100/9
5
50 °C 100/9
0
55 °C 100/8
5

75
ENGINE CHOICE
 Duty for equivalent loading
6.2.1-CONTINUOUS RUNNING DUTY (TYPE
S1)
For a motor suitable to this duty type, the rating at
which the machine may be operated for an unlimited
period is specified. This class of rating corresponds to
the duty type whose appropriate abbreviation is S1.
DEFINITION – The duty type S1 can be defined as
operation at a constant load maintained for sufficient
time to allow the machine to reach thermal equilibrium.
Where: ΔT – Time sufficient to allow the machine to
reach thermal equilibrium
6.2.2-SHORT-TIME DUTY (TYPE S2)
For a motor suitable to this duty type, the rating at
which the machine, starting at ambient temperature,
may be operated for a limited period is specified. This
class of rating corresponds to the duty type whose
appropriate abbreviation is S2.
DEFINITION – The duty type S2 can be defined as
operation at constant load for a given time, less than
that required to reach thermal equilibrium, followed by
a time de-energized and at rest of sufficient duration to
re-establish the equilibrium between the machine
temperature and that of the coolant temperature.
A complete designation provides the abbreviation of
the duty type followed by an indication of the duration
of the duty (S2 40 minutes).
 ΔTc – Operation time at constant load
 ΔT0 – Time de-energized
6.2.3-PERIODIC DUTY (TYPE S3-S8)
For a motor suitable to this duty type, the rating at which the machine may be operated in a
sequence of duty cycles is specified. With this type of duty, the loading cycle does not allow
the machine to reach thermal equilibrium.
This set of ratings is linked to a defined duty type from S3 to S8 and the complete
designation allows identification of the periodic duty.
If no otherwise specified, the duration of a duty cycle shall be 10 minutes and the cyclic
duration factor shall have one of the following values: 15%, 25%, 40%, 60%.
The cyclic duration factor is defined as the ratio between the period of loading, including
starting and electric braking, and the duration of the duty cycle, expressed as a percentage.

6.2.4-DUTY TYPE S3
(Intermittent periodic duty)
DEFINITION – The duty type S3 is defined as a
sequence of identical duty cycles, each including a time
of operation at constant load and a time de-energized
and at rest. The contribution to the temperature-rise
given by the starting phase is negligible.
A complete designation provides the abbreviation of the
duty type followed by the indication of the cyclic
duration factor (S3 30%).
 ΔT0 – Time de-energized and at rest
 Cyclic duration factor = ΔTc/T
6.2.5-THE DUTY TYPE S4
(Intermittent periodic duty with starting)
sequence of identical duty cycles, each cycle
including a significant starting time, a time of
operation at constant load and a time de-
energized and at a rest.
A complete designation provides the
abbreviation of the duty type followed by the
indication of the cyclic duration factor, by the
moment of inertia of the motor JM and by the
moment of inertia of the load JL, both referred to
the motor shaft (S4 20% JM = 0.15 kg m2 JL =
0.7 kg m2).
 ΔT* – Starting/accelerating time
 Cyclic duration factor = (ΔT* + ΔTc)/ T
(Intermittent periodic duty with electric braking)
consisting of a starting time, a time of operation
at constant load, a time of electric braking and a
time de-energized and at a rest.

77
ENGINE CHOICE
A complete designation refers to the duty type and gives the same type of indication of the
previous case.
 ΔTf – Time of electric braking
 Cyclic duration factor = (ΔT* + ΔTc + ΔTf)/ T
(Continuous-operation periodic duty)
consisting of a time of operation at constant load
and a time of operation at no-load. There is no
time de-energized and at rest.
A complete designation provides the abbreviation
of the duty type followed by the indication of the
cyclic duration factor (S6 30%).
 ΔT0 – Operation time at no load
 Cyclic duration factor = ΔTc/ΔT0
(Continuous-operation periodic duty with electric braking)
DEFINITION – The duty type S7 is defined as a sequence of identical duty cycles, each
cycle consisting of a starting time, time of operation at constant load and a time of electric
braking. There is no time de-energized and at
rest.
A complete designation provides the
abbreviation of the duty type followed by the
indication of both the moment of inertia of the
motor JM and the moment of inertia of the
load JL (S7 JM = 0.4 kg m2 JL = 7.5 kg m2).
 Cyclic duration factor = 1

(Continuous-operation periodic duty with related load / speed)
DEFINITION – The duty type S8 is defined as a sequence of identical duty cycles, each
consisting of a time of operation at constant load corresponding to a predetermined speed of
rotation, followed by one or more times of operation at other constant loads corresponding to
different speeds of rotation.
There is no time de-energized and at rest.
A complete designation
provides the abbreviation of
the duty type followed by the
indication of the moment of
inertia of the motor JM and by
the moment of inertia of the
load JL, together with the
load, speed and cyclic
duration factor, for each
speed condition (S8 JM = 0.7
kg m2 JL = 8kgm2 25kW
800rpm 25% 40kW 1250rpm
20% 25 kW 1000 rpm 55%).
 ΔTc1; ΔTc2; ΔTc3 – Operation time at constant load
 ΔTf1; ΔTf2 – Time of electric braking
 Cyclic duration factor = (ΔT*+ΔTc1)/T; (ΔTf1+ΔTc2)/T; (ΔTf2+ΔTc3)/T
6.2.10- NON-PERIODIC DUTY (TYPE S9)
Duty with non-periodic load and speed variations
For a motor suitable to this duty type, the rating at which the machine may be operated non-
periodically is specified. This
class of rating corresponds to
the duty type whose
appropriate abbreviation is
S9.
DEFINITION – The duty type
S9 is defined as a duty in
which generally load and
speed vary non-periodically
within the permissible
operating range. This duty
includes frequently appplied
overloads which may greatly
exceed the reference load.

79
ENGINE CHOICE
 ΔT* – Starting / accelerating time
 ΔTs – Time under overload
6.2.11- DUTY WITH DISCRETE CONSTANT LOADS AND SPEEDS (TYPE
S10)
For a motor suitable to this duty type, the rating at which the machine may be operated with
a specific number of discrete loads for a sufficient time to allow the machine to reach thermal
equilibrium is specified.
The maximum permissible
load within one cycle shall
take into consideration all
parts of the machine (the
insulation system, bearings or
other parts with respect to
thermal expansion).
The maximum load shall not
exceed 1.15 times the value of
the load based on duty type
S1. Other limits as regards the
maximum load may be given
in terms of limits of
temperature of the winding.
The minimum load may have
the value zero, when the
machine operates at no-load
or is de-energized and at rest.
This class of rating corresponds to the duty type whose appropriate abbreviation is S10.
DEFINITION – The duty type S10 is defined as the operation characterized by a specific
number of discrete values of load maintained for a sufficient time to allow the machine to
reach thermal equilibrium. The minimum load during a duty cycle may have value zero and
be relevant to a no- load or rest condition.
A complete designation provides the abbreviation of the duty type followed by the indication
of the per unit quantities p/Δt for the partial load and its duration, and by the indication of the
per unit quantity TL which represents the thermal life expectancy of the insulation system
related to the thermal life expectancy in case of duty type S1 with rated output, and by the
quantity r which indicates the load for a time de-energized and at rest (S10 p/Δt = 1.1/0.4;
1/0.3; 0.9/0.2; r/0.1 TL = 0.6).
Where:

 ΔΘ1; ΔΘ2; ΔΘ2 – Difference between the temperature rise of the winding at each of
the various loads within one cycle and the temperature rise based on duty cycle S1
with reference load
 ΔΘref – Temperature at reference load based on duty type S1 t1; t2; t3; t4: time of a
constant load within a cycle P1; P2; P3; P4: time of one load cycle
 (Pref: reference load based on duty type S1)
6.2.12- DUTY FOR EQUIVALENT LOADING
For a motor suitable to this duty type, the rating, for test purposes, at which the machine may
be operated at constant load until thermal equilibrium is reached and which results in the
same stator winding temperature rise as the average temperature rise during one load cycle
of the specified duty type.
This class of ratings, if applied, corresponds to the duty type designated “equ”.
6.3- GEOMETRIC CRITERIA:
The size of the machine can in some cases cause problems. We must therefore
check the position (horizontal or vertical) and the dimensions of the machine.

81
ENGINE CHOICE
7- EXERCISE:
An elevator consists of a mass cabin mc, a mass counterweight mp that can carry people for
a load m. The synoptic of this system is given below:
Moteur
Réducteur
Poulie
Contre
Poids
Cabine
+
Charge
The study will be done in steady state and it is
assumed that the moments of inertia are negligible.
Q 1. Give the expression of the torque on the shaft of the pulley. Calculate this torque
for a load of:
 - m = 200 kg ;
 m = 100 kg ;
 m = 50 kg ;
 m = 0 kg ;
Q 2. Show that the couple is constant. Deduce the minimum starting torque of the
motor.
Q 3. Give the mechanical characteristics of the engine necessary for its choice.
The elevator is located in a building of a ski resort at an altitude of 2000 m. The room of IP
235 at a maximum temperature of 50 ° C.
The engine chosen at a nominal power of 1 hp, for a rotation frequency of 3000 rpm. Its
thermal insulation class is A and its is 60 ° C, its IP is 55. Service S1.
Q 4. Determine if the constraints of the environment should induce a change in the
choice of the machine. (Declassification with respect to temperature, derating from
altitude, IP). If so calculate the new engine power.
Q 5. Look for engine service knowing that it has a starting and braking device.
Q 6. It is assumed as a first approximation that the engine runs for 2 hours a day. Given
this data, and previous results, calculate the life of the engine if the temperature
increases by 10 ° C.
Data :
- m = 200 kg;
- mp = 220 kg;
- mc = 170 kg;
- the reduction ratio of the reducer of
Speed ist de 1 / 149;
- Rendement du réducteur 70 %
- the radius of the pulley is 0,305 m;
- The vertical speed of movement of the
cabin is 0,317 m/s
- gravity acceleration 9,81 m.s -2
we neglect :
- the moment of inertia of the pulley;
- dry and viscous rubbing;
- the mass of the cable;

DC MOTOR

83
DC MOTOR
1- OBJECTIVE
 Implement electrical wiring according to the standards
 Establish the list of required equipment in order to make the industrial electrical wiring
2- PRINCIPE :
A moving conductor in a magnetic field is the seat of an electromotive force (EMF) whose
direction is given by the rule of the three fingers of the left hand. If a turn turns in the
magnetic field, the two conductors are subjected to two additional electromotive forces. A
generator is made.
The system is reversible, ie if a current is passed through the coil immersed in a
magnetic field, the coil is subjected to two forces that are added. We realize an engine.A
driven DC machine operates as a generator, and if it is powered, it operates as a motor. It is
REVERSIBLE.
3- FUNDAMENTAL EQUATIONS:
3.1- ELECTROMOTIVE FORCE E (EMF)



 k
ouE
E )
'
(
With
  flux in Weber,
  in rad / s,
 k = 2..p.N / a.
o p: number of pairs of poles,
o a: number of winding channels,
o N: number of conductors of the armature.
3.2- OHM'S LAW:
Applied to an Engine Applied to a Generator
I
r
E
U 

 I
r
E
U 

 '

Ia [industrial automation part 1]

Ia [industrial automation part 1]

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