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 

 '

E R I
U
E’ R I
U
 With E electromotive force,
 E 'force against electromotive
 R resistance of the armature
 I current in the armature.
3.3- SPEED
Using previous relationships
For an engine For a generator.





k
I
r
U





k
I
r
U
3.4- THE POWER :
I
E
P 
 or I
E
P 
 '
3.5- ENGINE TORQUE :
I
k
P
T 




4- CONSTRUCTION :
 The DC machine consists mainly of:
o A magnetic circuit to channel the flow;
o An inductive electric circuit to produce the flux and an induced electric circuit;
o A mechanical part to fix the different elements with respect to each other.
4.1- THE MAGNETIC CIRCUIT:
 It consists of two parts:

85
DC MOTOR
 The inductor producing the flux and constituting the fixed part;
 The armature, mobile in rotation, which is the seat of the electromotive forces with
between the two parts "the gap".
 The inductive poles are made of metal and consist of a stack of magnetic sheets (steel
with 3.5% silicon). This solution is retained to avoid eddy current losses due to the shape
of the armature (notches).
 The auxiliary poles are placed between the main poles to facilitate switching. They
suppress sparks that are produced when the direction of current is inverted in the turns of
the armature. They are in series with the main poles of the inductor.
 The body provides two functions: It conduct the magnetic field lines and ensures the
connection between the different mechanical parts.
 The rotating magnetic circuit. The flux is variable at each turn, hence the need to flip the
magnetic circuit to reduce losses by Hysteresis and Foucault current (sheet with 3%
silicon thickness of 0.35 mm).
4.2- ELECTRICAL CIRCUITS:

4.2.1-THE INDUCTOR:
It creates the magnetic flux in the main poles. The excitation power is about 2 to 3% of the
total power (5% for small machines).
The excitation winding can be shunted (or shunt (large number of turns in fine wires)) or in
series (small number of coils in thick wire) with the armature.
4.2.2-THE ARMATURE:
The winding of the armature is composed of a large number of sections formed of turns
whose ends are connected to two consecutive blades of the commutator.
4.2.3-THE COMMUTATOR:
It provides the connection between the rotating conductors and the external circuit. It
transforms the alternating current of the armature into direct current.
Crossing the neutral line, the commutator reverses the polarity of the conductors so that the
forces are always in the same direction.
The connection is made by graphite brushes which must be monitored for wear.
5- CHARACTERISTICS :
The DC machine is characterized by:
 The nominal power of operation;
 The armature voltage;
 The speed of rotation;
 The couple;
 The power supply of the inductive circuit.
Characteristics of the operation according to the power supply of the inductor:
Current Speed: Current Torque:

87
DC MOTOR
Torque Speed
Note: When the inductive flux tends to 0, the velocity tends to infinity. It's the runaway.
6- USES OF DC MOTOR:
6.1- INDEPENDENT EXCITATION:
This engine is characterized by a constant speed. It is most often used in independent
excitation, with speed regulation.
6.2- SERIAL EXCITATION MOTOR:
This engine has a very high starting torque, it is suitable for all electric traction applications,
however, it presents risks of runaway empty.
7- IDENTIFICATION :
The nameplate gives indications similar to those of three-phase motors with special features.
nb: Bridges are usually powered by rectifier systems.
Example: LSK 1604 indicates the LSK series; 160 the
axis height; 4 the number of poles.
We find :
 The electric power;
 The speed in rpm;
 Armature voltage and current;
 The voltage and intensity of excitation.

8- STARTING A DC MOTOR:
At power up, the motor does not rotate so the electromotive force is zero. The called current
is limited only by armature resistance. This results in a strong
starting current. To limit this current between 1.2 and 2 In, the
resistor is placed in series with the armature.
Contactor starter:
 Km1: forward;
 Km2: reverse,
 K1 and K2 start contactor.
When starting a DC motor in Seri wiring, do not under any circumstances cut the excitation
before the armature.
9- EXERCICE :
A passenger transport system requires a DC motor to meet the specifications. It must
provide a torque of 58 Nm for a speed of 900 rpm.
Q 1. Calculate the useful power that the engine must supply. Look for the
characteristics of this engine in the course documentation.
Q 2. Give the model of the course the nameplate of the engine.
Q 3. We want a starting current of 2 In maximum. Calculate the starting resistances. We
will take k = 3.385.
Q 4. The motor is controlled by contactors. It works in both directions of rotation. Give
the power scheme for this operation. Using the telemechanical documents, look for
the reference of the different constituents of the power circuit.

89
INDUCTION Motor
INDUCTION Motor

1- OBJECTIVE
2- INTRODUCTION
An induction motor or asynchronous motor is an AC electric motor in which the electric
current in the rotor needed to produce torque is obtained by electromagnetic induction from
the magnetic field of the stator winding. An induction motor can therefore be made without
electrical connections to the rotor. An induction motor's rotor can be either wound type or
squirrel-cage type.
Three-phase squirrel-cage induction motors are widely used as industrial drives because
they are rugged, reliable and economical. Single-phase induction motors are used
extensively for smaller loads, such as household appliances like fans. Although traditionally
used in fixed-speed service, induction motors are increasingly being used with variable-
frequency drives (VFDs) in variable-speed service. VFDs offer especially important energy
savings opportunities for existing and prospective induction motors in variable-torque
centrifugal fan, pump and compressor load applications. Squirrel cage induction motors are
very widely used in both fixed-speed and variable-frequency drive (VFD) applications.
The conversion of electrical energy is 80% by three-phase asynchronous motors thanks to
their simplicity of conversion, their robustness and their ease of starting.

91
INDUCTION Motor
3- GENERAL PRINCIPLE OF THE CONVERSION OF ELECTRICAL
ENERGY INTO MECHANICAL ENERGY:
This conversion is done with rotating machines that obey
the laws of electromagnetism.
The action of a magnetic field on an electric current
produces a force whose expression is given by the relation:
F = B I L.
It is this force that is channeled to realize an engine.
4- PRINCIPLE OF OPERATION
In both induction and synchronous motors, the AC power supplied to the motor's stator
creates a magnetic field that rotates in synchronism with the AC oscillations. Whereas a
synchronous motor's rotor turns at the same rate as the stator field, an induction motor's rotor
rotates at a somewhat slower speed than the stator field. The
induction motor stator's magnetic field is therefore changing or
rotating relative to the rotor. This induces an opposing current in
the induction motor's rotor, in effect the motor's secondary
winding, when the latter is short-circuited or closed through
external impedance. The rotating magnetic flux induces currents
in the windings of the rotor; in a manner similar to currents
induced in a transformer's secondary winding(s).
The induced currents in the rotor windings in
turn create magnetic fields in the rotor that
react against the stator field. Due to Lenz's
Law, the direction of the magnetic field created
will be such as to oppose the change in current
through the rotor windings. The cause of
induced current in the rotor windings is the
rotating stator magnetic field, so to oppose the
change in rotor-winding currents the rotor will
start to rotate in the direction of the rotating
stator magnetic
field. The rotor
accelerates until the magnitude of induced rotor current and
torque balances the applied mechanical load on the rotation of
the rotor. Since rotation at synchronous speed would result in no
induced rotor current, an induction motor always operates
slightly slower than synchronous speed. The difference, or "slip,"
between actual and synchronous speed varies from about 0.5%
to 5.0% for standard Design B torque curve induction motors. The induction motor's essential
character is that it is created solely by induction instead of being separately excited as in
synchronous or DC machines or being self-magnetized as in permanent magnet motors.
E F B
I

An induction motor can be used as an induction generator, or it can be unrolled to form a
linear induction motor which can directly generate linear motion.
5- PRINCIPLE OF OPERATION OF THE ASYNCHRONOUS
MACHINE:
5.1- CREATING A ROTATING FIELD:
 If three identical coils placed at 120 ° are
fed by a three-phase AC voltage:
 A magnetized needle, placed in the
center, is rotated; So there is a creation of a
rotating field.
 The needle is replaced by a metal disc
made of aluminum or copper. It is driven in the
same direction as the magnetic needle.
 If two of the three three-phase power
leads are reversed, the needle or disc rotates in
the opposite direction.Principe de fonctionnement
de la machine asynchrone :
The three AC fields produced by the three-phase-fed coils are composed to form a rotating
field. The rotating magnetic field creates induced currents in the metal disk; These, according
to Lenz's law, oppose the cause that gave rise to them, and cause a magnetomotive force
that drives the disk in rotation.
The part containing the coils creating the magnetic field is called "STATOR". The moving part
under the influence of the magnetic field is called "ROTOR".
6- CONSTITUTION OF AN ASYNCHRONOUS MACHINE:

93
INDUCTION Motor
6.1- THE STATOR CIRCUIT:
To produce a rotating magnetic field, a winding or stator winding is realized, with coils
housed in stator slots.
6.2- ROTOR CIRCUIT:
The rotor is the seat of electromotive forces produced by the action of the magnetic field on
the induced currents of the rotor circuit.
There are two types of rotor:
 The rotor in short circuit or squirrel cage. The winding consists of copper or aluminium
metal bars embedded in the magnetic circuit and short circuited by two rings.
 The wound rotor: the winding consists of three star-coupled windings connected to
the external circuit by three rings. This type of engine requires special equipment that
allows obtaining a progressive start torque.
6.3- WINDING CONCEPT:
In three-phase, the stator is composed of three independent windings. Each of these
windings is composed of sections housed in notches of the magnetic circuit.
 The turn (le spire): it includes a wire to go and a return wire, two active wires.
 The beam (le Faiceau): this is the set of conductors placed in a notch and travelled in
the same direction by the current of a phase.
 Section: It is formed by two beams connected by the coil heads. It is characterized by
its number of turns and its pitch.
 Section steep: This is the distance between two consecutive neutral lines. It is also
called diametrical
7- ELECTRICAL FORMULAS :
N N
S
1 Spire
1
faisceau
1
section
.
Input
U-I Cos
Numbers of phases
O
P(w) N(rpm)
T(Nm)

The asynchronous motor transforms the electrical energy supplied by the single-phase or
three-phase alternating current into mechanical energy. It is characterized by input quantities
that are electrical and by output quantities that are mechanical.
 The electrical power absorbed by a three-phase asynchronous motor is:
Pa: Power in W (Watt); U: Voltage in V (Volts); I: Current in A (Amperes);
Cos : cosine of the phase shift angle between current and voltage.
Note: The current and voltage measurements can not give the power, Cos can vary
between 0.1 and 0.2 empty until 0.9 at full load.
 The mechanical power is that obtained on the motor shaft:
Pu: Power in W (watt); Tu: Engine torque Newton-meter (Nm);
: angular velocity in radians per second (rad / s); n: Rotational speed in revolutions per second (rps).
 Rated power: This is the mechanical power available on the motor shaft at its rated
speed.
 Rated speed: The nominal speed is the speed at nominal power. We distinguish the
speed of synchronism (speed of the rotating field):
Where f is the frequency of the power supply, p is the number of magnetic poles, and ns is
the synchronous speed of the machine. For f in Hertz and ns in RPM, the formula becomes:
 Slip, s is defined as the difference between synchronous speed and operating speed,
at the same frequency, expressed in rpm, or in percentage or ratio of synchronous
speed. Thus
Where ns is stator electrical speed, nr is rotor
mechanical speed.
Slip, which varies from zero at synchronous speed
and 1 when the rotor is at rest, determines the
motor's torque.

Cos
I
U
Pa 


 3


 u
u T
P

95
INDUCTION Motor
 Nominal current: This is the value of the current absorbed by the machine at rated
power and rated voltage.
 Power factor and efficiency: The efficiency and the power factor change according to
the load. They are given for the nominal power of the machine.
Pu: rated useful power; U: voltage between nominal phase; I: rated current; Cos
: power factor; : efficiency.
Ratio:
n
d
I
I
This is the ratio between the
current absorbed at start-up and the rated
current. In case of direct start, it varies from
6 to 8.
Ratio:
n
d
T
T
This is the ratio between the
starting torque and the nominal torque. It is
between 1.5 and 3 depending on the
construction of the machine.
8- STANDARD TORQUE
Speed-torque curves for four induction motor types: A) Single-phase, B) Polyphase cage, C)
Polyphase cage deep bar, D) Polyphase double cage
The typical speed-torque relationship of a standard NEMA Design B polyphase induction
motor is as shown in the curve at right. Suitable for most low performance loads such as

 Cos
I
U
Pa 



 3
0
1
2
3
4
5
6
7
8
l /l n
0,25 0,5 0,75 1 N/N n
Ns

centrifugal pumps and fans, Design B motors are constrained by the following typical torque
ranges:
 Breakdown torque (peak torque), 175-300% of rated torque
 Locked-rotor torque (torque at 100% slip), 75-275% of rated torque
 Pull-up torque, 65-190% of rated torque.
Over a motor's normal load range, the torque's slope is approximately linear or proportional
9- COUPLING
Induction motor is composed of three coils. One coil per phase. Each coil has a nominal
voltage and nominal current. These values are written on the rating plate of the motor.
The voltage of the power supply is important to know as it will define what will be the
coupling of the motor. An Induction Motor has two voltages with a ratio of √3. E.g. 220/380V
The lowest voltage is the maximum voltage a coil can handle. In this case, the voltage of the
power supply in important to know. For a power supply of 220/380V, the voltage between
phases is 380V.
There are two types of connection (coupling) for an induction motor:
 Star, on end of the three coils are
connected together.
o U2, V2, W2 connected
together,
o Power supply on U1, V1,
W1.
Delta, all coils are in series.
o U1 connected to W2
o W1 connected to V2
o V1 connected to U2

97
INDUCTION Motor
On connection plate:
Star Delta
Coupling depending of the power supply (Network) and the motor voltage rating
10- STARTING AN ASYNCHRONOUS MACHINE:
There are three basic types of competing small induction motors: single-phase, split-phase
and shaded-pole types and small polyphase motors.
In two-pole single-phase motors, the torque goes to zero at 100% slip (zero speed), so these
require alterations to the stator such as shaded-poles to provide starting torque. A single
phase induction motor requires separate starting circuitry to provide a rotating field to the
motor. The normal running windings within such a single-phase motor can cause the rotor to
turn in either direction, so the starting circuit determines the operating direction.
Self-starting polyphase induction motors produce torque even at standstill. Available squirrel
cage induction motor starting methods include direct-on-line starting, reduced-voltage reactor
or auto-transformer starting, star-delta starting or, increasingly, new solid-state soft
assemblies and, of course, variable frequency drives (VFDs).
Polyphase motors have rotor bars shaped to give different speed-torque characteristics. The
current distribution within the rotor bars varies depending on the frequency of the induced
current. At standstill, the rotor current is the same frequency as the stator current, and tends
to travel at the outermost parts of the cage rotor bars (by skin effect). The different bar
shapes can give usefully different speed-torque characteristics as well as some control over
the inrush current at startup.
Network Motor 127/220V 220/380V 380/660V
127/220V Y  Under Voltage
220/380V Impossible Y 
380/660V Impossible Impossible Y

In wound rotor motors, rotor circuit connection through slip rings to external resistances
allows change of speed-torque characteristics for acceleration control and speed control
purposes.
10.1- CASE OF THE STARTING TORQUE:
 For an Induction Motor to start, the torque
demanded by the load on startup must be less
than the starting torque of the machine.
 The machine produces the starting and stabilizes
at the point F which is the point of operation of
the system.
 This point must be as close as possible to point
N (nominal point of the machine) to obtain
maximum energy efficiency.
10.2- DIRECT ON LINE :
 Direct startup of an asynchronous machine causes a high starting current. Id = 6 to 8
In.
 Make sure that the protections are not tripped: fuse use aM.
 To avoid the disadvantage of the fuse aM (melting delay), the motor is protected
against overloads by a thermal tripping device
10.3- STAR – DELTA STARTING :
This type of startup avoids the disadvantage of the strong
current at startup. Indeed by using a reduced voltage at
startup, the current is limited.
3

  d
d
I
I
3

  d
d
T
T
 The disadvantage lies in the weakness of the
starting torque.
 Star Delta Starter can only be used if the starter-
resistant torque is zero or very low.
10.4- STATOR STARTER : STARTING BY ELIMINATING STATOR RESISTORS:
Always to eliminate the intensity peak at startup, work under
reduced voltage. This reduced voltage is achieved by
inserting stator resistors in series with the motor. We can
achieve a start in several times.
0
T
/Tn
1
2
3
4
0,25 0,5 0,75 N/Ns
Couple résistant
opposé par la charge
Couple Moteur
1
F
N

99
INDUCTION Motor
1.1.1. Torque and current curves:
In this type of starting, the intensity absorbed
by the motor is proportional to the voltage
applied to the motor.
On the other hand, the motor torque is
proportional to the square root of the voltage
applied to the motor.
1.1.2. Wiring diagrams:
10.5- START BY ELIMINATION OF ROTORS RESISTORS:
This process, by the addition of resistors in the rotor startup, reduces the current; the torque
meanwhile, is translated.

10.5.1- TORQUE AND CURRENT CURVES:
This type of start allows for a lower absorbed current to obtain a torque at the start.
10.5.2- WIRING DIAGRAMS

101
INDUCTION Motor
10.6- VARIATION OF THE OPPOSITE TORQUE BY THE LOAD
For correct motor operation, the torque opposite
the load must not exceed the point M because it
causes the machine to stop by "unhooking" of
the rotor on the stator.
For a zero resistance torque, the speed of
rotation of the motor is close to the speed of
synchronism (n / ns ~ 1)
This gives the maximum variation of the speed
as a function of the load.
11- SPEED CONTROL
11.1.1- RESISTANCE
Before the development of semiconductor power electronics, it was difficult to vary the
frequency, and cage induction motors were mainly used in fixed speed applications.
Applications such as electric overhead cranes used DC drives or wound rotor motors (WRIM)
with slip rings for rotor circuit connection to variable external resistance allowing considerable
range of speed control. However, resistor losses associated with low speed operation of
WRIMs is a major cost disadvantage, especially for constant loads. Large slip ring motor
drives, termed slip energy recovery systems, some still in use, recover energy from the rotor
circuit, rectify it, and return it to the power system using a VFD.
11.1.2- CASCADE
The speed of a pair of slip-ring motors can be controlled by a cascade connection, or
concatenation. The rotor of one motor is connected to the stator of the other. If the two
motors are also mechanically connected, they will run at half speed. This system was once
widely used in three-phase AC railway locomotives, such as FS Class E.333.
11.1.3- VARIABLE-FREQUENCY DRIVE
In many industrial variable-speed applications, DC and WRIM drives are being displaced by
VFD-fed cage induction motors. The most common efficient way to control asynchronous
motor speed of many loads is with VFDs. Barriers to adoption of VFDs due to cost and
reliability considerations have been reduced considerably over the past three decades such
that it is estimated that drive technology is adopted in as many as 30-40% of all newly
installed motors.
0
T
/Tn
1
2
3
4
0,25 0,5 0,75 N/Ns
Maximun speed
variation
1
Maximum Torque
Variation
M
N

Typical speed-torque curves for different motor input frequencies as for example used with
variable-frequency drives
12- IN SUMMARY
Starter Direct Star Delta Stator Rotor
Initial current 4 to 8 In 1,3 to 2,6 In 4,5 In 2,5 In
Staring Torque 0,6 to 1,5 Tn 0,2 to 1,5 Tn 0,6 to 9,85 Tn 2,5 Tn
Average
duration
2 to 3 s 3 to 7 s 7 to 12 s 2,5 to 5 s
Advantages Simple and
costless starter
High starting
torque
Good ratio
Torque / Curent
Not too
expensive
No supply cut,
limitation of
Inrush current
Very good ration
Torque/Current
No power cut
Disadvantage High Inrush
current
Strong stating
Small staring
Torque, Power
cut when
changing from
Star to Delta
Need of
resistances
Small reduction
of the Inrush
Current
Winding Rotor
more expensive
Nedd of
resistances
Applications Small motor
power up to
5KW
Induction motor
starting without
loads
Engin with high
Inertia
Progressive
starting
Lift

103
INDUCTION Motor
13- NAME PLATE :
Information :
 Reference
 Serial Number
 IP
 IK
 Temperature
 Insulation class
 Duty
 Max altitude
 Weight
 Voltages
 Currents
 Speed
 Power
 DPF (Displacement Power Factor)
 Frequency
 Efficiency
 …

14- EXAMPLE OF INDUCTION MOTOR

105
INDUCTION Motor

15- MOTOR MOUNTING CODES
Proper motor installation and mounting position is essential in obtaining top-quality operation,
efficient performance, and maximum reliability. Sometimes, however, there is confusion
about the many different ways a motor can be installed.
There are two different standards—NEMA and IEC— which you will see when looking at
electric motor mounting positions. Although they are generally comparable, there are slight
differences between the two.
The standard IEC mounting position places the junction box on the top of the motor, known
as the IM B3 mounting position in IEC frame (or F3 in NEMA frames). On the other hand,
the NEMA standard mounting position is referred to as F1, with the junction/conduit box
located on the left side of the motor facing the output shaft.
The design of most motors is such that they can usually be operated in many mounting
positions, unless indicated otherwise. Some mounting positions, however, require additional
construction modifications to achieve optimal performance. For example, shaft-up or shaft-
down outdoor applications may require drilling of additional drain holes, drip covers and
stronger bearings to support heavy loads. Don't just assume you can bolt any motor in any
orientation!

107
INDUCTION Motor
16- EXERCICES :
In a ski resort in the Alps, a lift is driven by a three-phase asynchronous machine. The
departure station is located at an altitude of 1250 m and that of arrival at an altitude of 1650
m. The length of the ski lift is 1000 m. It consists of a 29.6 mm diameter cable and 60 60 kg
boats that can support a load of 160 kg. The speed of movement of the nacelles is 2.5 m / s
and the maximum acceleration at startup defined by the standard is 0.7 m / s2
L = 1000 m
Starting Station
1250 m
Arrival Station 1650
m
The mechanical system is as follow :
 Diameter of the pulley: 3.5 m;
 reduction ratio of all gear units: 0.009319;
 Overall efficiency of gearboxes: 0.773;
 We will note:
• P and TP angular velocity and torque on the pulley shaft;
• m and Tm the angular velocity and the torque on the motor shaft;
The purpose of this exercise is to choose the engine of the ski lift.
Q 5. Determine the rise time of the nacelles.
Q 6. Calculate the angular velocity and rotational frequency of the pulley and the motor.
Motor
Gear
Belt
Pulley

Q 7. Knowing that the torque opposite the load on the pulley is 33 160 N.m in steady
state, calculate the resisting torque on the motor shaft.
Q 8. Deduce the mechanical power that must provide the engine in steady state.
Q 9. The maximum acceleration allowed for passenger transport is 0.7 m / s2. Calculate
the angular acceleration (d/dt) on the pulley shaft and then on the motor shaft.
Q 10. Knowing that the total moment of inertia of the system brought back on the motor
shaft is 9.16 kg.m2, calculate the accelerating torque necessary to meet the
specifications. Deduce the minimum starting torque of the machine. Calculate then
ratio Cd / Cn.
Q 11. The maximum temperature of the room in which the motor is located is 30 ° C.
Check if corrections are needed for the choice of engine.
Q 12. Using the above calculations, knowing that the power supply is three-phase 3 *
400 V 50 Hz, select the motor in the LEROY SOMER documents.
Q 13. Give the nameplate of this engine.
Q 14. What should be the coupling of the windings?
Q 15. Calculate the starting current of the motor. What precautions should be taken?
Q 16. Give the maximum value of the torque and its value at startup.
Q 17. Give the outside dimensions of the engine.
Q 18. In steady state, determine the stable operating point of the motor. We will assume
the constant torque. Deduce the value of the slip and the speed of the nacelles.
Q 19. The torque can actually vary from 300 to 600 N.m. Give the theoretical variation
range of the motor rotation frequency.
Q 20. To avoid a sudden start, it is desired to use a soft start device. What types of
startup can I use? Justify your answer.

109
VARIABLE-Speed
VARIABLE-Speed

1- OBJECTIVE
 Drawing and electrical circuit according to the standards
2- PREAMBLE :
The speed variation of electric machines is more and more used. Advances in power
electronics open up interesting prospects.
The operating principle can be represented according to the following diagram:
The setpoint is the control variable of the drive.
Variateur M
Réseau
Consigne
n
Consigne
3- VARIATION OR REGULATION:
3.1- DRIVER:
Allows variable speed without guaranteeing stability over
time;
During operation elements may vary:
 The resistant torque;
 The network voltage;
 The temperature;
And cause a change in the actual speed compared to the setpoint.
The speed variation is poorly adapted to low speeds.
3.2- CONTROLER :
 Maintains the actual speed in accordance with a very
small deviation from the set speed despite
disturbances;
 To do this, the controller must be constantly informed
of the actual speed of the motor via a speed sensor..

111
VARIABLE-Speed
4- BASIC EQUATIONS:
4.1- THE DC MACHINE:
The equivalent diagram gives the equations of the DC machine with separate excitation:
E
r
U
I
p: number of pairs of poles
a: number of winding paths;
N: number of active drivers;
: useful flow by poles in Webers;
n: speed of rotation in rps;
K: speed constant;
P: power absorbed in W;
Pe: electromagnetic power in W;
Ce: electromagnetic torque in Nm
From these equations we can write the speed as:






k
I
r
U
4.2- THE INDUCTION MOTOR :
Equivalent diagram:
A phase of an asynchronous machine brought back to primary allows us to define the
following equivalent schema:
V
I1 I2
I0
Rm Xm R2 / g
l
The equations of the asynchronous machine give
us:
f: frequency of the supply network;
p: number of pairs of poles;
ns: synchronism speed in rps;
n: speed of rotation in rps;
g: sliding of the machine;
The power transmitted to the rotor is given by the relations:
s
e
tr C
I
g
R
P 




 2
2
2
3 and
 2
2
2
2
2












l
g
R
V
I









 k
n
N
a
p
E

2
I
E
P
I
U
P
I
r
E
U
e 






I
k
I
E
P
C e
e 








 
g
n
n s 
 1
s
n
p
f 


From there we can write:
The study of this relationship shows that the
maximum torque is
2
2 .
.
.
.
1
.
.
2
R
l
g
l
g
R
C
C eMax
e



 and
2
.
.
2
.
3








V
l
p
CeMax
Ce: electromagnetic torque;
p: number of pairs of poles;
R2: rotor resistance;
: pulsation of the network;
l: rotor reactance;
V: supply voltage;
5- THE SPEED VARIATION OF A DC MACHINE:
According to the equations, the speed variation can be obtained in two ways:
5.1- ACTION ON THE SUPPLY VOLTAGE U:
For a constant torque (I is constant) and a constant excitation flux, a variation of the speed is
obtained by a variation of the supply voltage.



'.
.
k
I
r
U
n
5.2- ACTION ON THE FLOW  :
For a constant torque and a constant voltage, the speed variation is obtained by a variation
of the excitation flux. This method is used when the nominal speed is obtained by variation of
U. A decrease of the flow increases the speed.
5.3- RÉGULATION :
0
C
/Cn
1
2
3
4
0,2
5
0,5 0,75 N/Ns
1
2
2
2
.
.
.
.
1
.
.
.
3
R
l
g
l
g
R
V
l
p
Ce












113
VARIABLE-Speed
The regulation is of the double loop type:
 Speed loop: for a given setpoint, the speed is kept constant regardless of the load;
 Current Loop: This loop supports load variation (hence I) to keep the speed constant.
If the load exceeds a permissible value (adjustment of Imax on the drive), the speed
is no longer kept constant but the current absorbed by the motor is limited.
The drive card is generally composed of a rectifier bridge controlled by thyristors.
6- SPEED VARIATION OF THREE-PHASE ASYNCHRONOUS
MACHINES:
According to the equations, the speed variation can be obtained by:
6.1- ACTION ON THE NUMBER OF PAIRS OF POLES:
This is the case of motors with separate windings or DAHLANDER type. There is an
action on the number of pairs of poles.
6.2- TWO SPEED MOTOR OF TYPE "DALHANDER":
The formula fs = p ns shows that the speed can be varied by changing the number of poles.
Let the representation of the windings of a phase:
 If we supply the simplified winding in E1, we
obtain 4 poles;
 If the simplified winding is supply to E2, 2
poles are obtained.
This solution requires the inputs and midpoints of the phases to be accessible for coupling
6.2.1-COUPLING PATE

6.2.2-POSSIBLE CONNECTIONS
Connection Low Speed : Connection High Speed :
6.3- ACTION ON THE SLIP:
Slip variation can only be used if the motor is a wound rotor. By inserting rotor resistors, it is
possible to obtain several operating points. (Modification of R2). (At constant frequency and
voltage)
L1 L2 L3
L2 L1 L3

115
VARIABLE-Speed
The speed depends:
 The value of the resistances;
 The characteristic of the engine torque:
 1 Natural curve of the motor (without
rotor resistors);
 2 Curve with reliable rotor resistors;
 3 and 4 Curves with larger rotor
resistances.
6.4- FREQUENCY ACTION:
The speed is directly related to the
frequency of the supply voltage. So a
variation of f makes it possible to vary the
speed. This method is commonly used for
powers below 500 kW. It is important to
keep the V / f ratio constant because it
gives a constant torque. (See equations).
So a variation of f is subject to a variation of
V.
In this case CeMax is constant and the
characteristics of couples are translated
horizontally.
This type of control is very common because it allows operation of the machine at any point
of the torque-speed characteristic.
6.4.1-PRINCIPLE OF OBTAINING OPERATION AT CONSTANT V / F:
The single-phase or three-phase voltage of the network is converted into a DC voltage via
the rectifier bridge and the filter capacitors.
 This DC voltage is cut by an inverter bridge to give a succession of pulses of variable
width (PWM), modulation of pulse width.
1
4
3 2
Cr
Ns
C
n
n1 n2 n3 n4
0
C /Cn
1
2
3
4
N
Ns1
Ns1
Ns1
Ns1
Ns1
V1/f1
V2/f2
V3/f3
V4/f4
V5/f5

 The adjustment of the width of the pulses and their repetition make it possible to
obtain a variable frequency while maintaining the constant V / F ratio;
 The cutting, according to the PWM technique, ensures a smooth and steady rotation
of the machines thanks to a form of output current close to the sinusoid;
 The inductance of the motor realizes the smoothing of the current;
6.4.2-OUTPUT CHARACTERISTICS:
 Frequency converters provide higher frequencies than the network frequency;
 Make sure that the engine supports speeding.
6.4.3-CURRENT AND VOLTAGE CURVES AT THE MOTOR TERMINALS:
The electronic starter is based on a gradual rise in the motor supply voltage during the start-
up phase.
The voltage variation is obtained via a dimmer whose circuit consists of six thyristors
mounted "head-to-tail" by two in each phase of the network.compose de six thyristors montés
“tête bêche” par deux dans chaque phase du réseau.
As a function of the time and the starting time of the thyristors, the dimmer makes it possible
to deliver a variable effective voltage across the motor and at a fixed frequency.
The control of the Dimmer is usually done by a voltage ramp.
The advantages of this type of starter are:
 Mechanics:
o Elimination of sudden starts;
o Reduced wear of mechanical transmissions;

117
VARIABLE-Speed
 Electric:
o Reduction of the dimensioning of the network;
o Possibility of cascading several engines;
o Reduction of starting current.
The major disadvantage of this type of starter is the starting torque which is very low. This
type of starter is mainly used for machines with zero starting torque. Exp. : Fan, Pumps ...
An example of electronic starter is the DIJISTART or Altistart.
7- DIFFERENT STRUCTURES OF VARIABLE SPEED DRIVES
DEPENDING ON THE MACHINES ORDERED:
Type of Converter Functional
Diagrams
Output Voltage
curve
Quadrants Type of
Motor
AC/DC
Controled Rectifier
Mixt Bridge
Unidirectional
DC
Machine
with
external
excitation
or with
permane
nt
magnet
Full Bridge
reversible Single Phase
Full Bridge
unidirectional
Full Bridge
reversible

Type of Converter Functional
Diagrams
Output Voltage
curve
Quadrants Type of
Motor
DC/DC
Chopper
From one to
four quadrants
depending of:
The type of
the bridge
The type of
the control
The type of
the power
supply
DC
Machine
with
serial
excitation
or with
permane
nt
magnet
AC/AC
Dimer
Vrms variable, fixe
frequency
Induction
Motor
with
Squirrel
cage or
winded
rotor
Use as
Starter
AC/AC
Breaking Module * With
breaking
module
Induction
Motor
with
Squirrel
cage

119
VARIABLE-FREQUENCY DRIVE

1- INTRODCUTION
A variable-frequency drive (VFD; also termed adjustable-frequency drive, “variable-
voltage/variable-frequency (VVVF) drive”, variable speed drive, AC drive, micro drive or
inverter drive) is a type of adjustable-speed drive used in electro-mechanical drive systems
to control AC motor speed and torque by varying motor input frequency and voltage
VFDs are used in applications ranging from small appliances to large compressors. About
25% of the world's electrical energy is consumed by electric motors in industrial applications,
which can be more efficient when using VFDs in centrifugal load service; however, VFDs'
global market penetration for all applications is relatively small.
Over the last four decades, power electronics technology has reduced VFD cost and size
and has improved performance through advances in semiconductor switching devices, drive
topologies, simulation and control techniques, and control hardware and software.
VFDs are made in a number of different low- and medium-voltage AC-AC and DC-AC
topologies.
2- SYSTEM DESCRIPTION AND OPERATION
A variable-frequency drive is a device used in a drive system consisting of the following three
main sub-systems: AC motor, main drive controller assembly, and drive/operator interface.
2.1- AC MOTOR
The AC electric motor used in a VFD system is usually three-phase induction motor. Some
types of single-phase motors or synchronous motors can be advantageous in some
situations, but generally three-phase induction motors are preferred as the most economical.
Motors that are designed for fixed-speed operation are often used. Elevated-voltage stresses
imposed on induction motors that are supplied by VFDs require that such motors be
designed for definite-purpose.
2.2- CONTROLLER
The VFD controller is a solid-state power electronics conversion system consisting of three
distinct sub-systems: a rectifier bridge converter, a direct current (DC) link, and an inverter.
Voltage-source inverter (VSI) drives are by far the most common type of drives. Most drives
are AC-AC drives in that they convert AC line input to AC inverter output. However, in some

121
applications such as common DC bus or solar applications, drives are configured as DC-AC
drives. The most basic rectifier converter for the VSI drive is configured as a three-phase,
six-pulse, full-wave diode bridge. In a VSI drive, the DC link consists of a capacitor which
smooths out the converter's DC output ripple and provides a stiff input to the inverter. This
filtered DC voltage is converted to quasi-sinusoidal AC voltage output using the inverter's
active switching elements. VSI drives provide higher power factor and lower harmonic
distortion than phase-controlled current-source inverter (CSI) and load-commutated inverter
(LCI) drives (see 'Generic topologies' sub-section below). The drive controller can also be
configured as a phase converter having single-phase converter input and three-phase
inverter output.
Controller advances have exploited dramatic increases in the voltage and current ratings and
switching frequency of solid-state power devices over the past six decades. Introduced in
1983, the insulated-gate bipolar transistor (IGBT) has in the past two decades come to
dominate VFDs as an inverter switching device.
In variable-torque applications suited for Volts-per-Hertz (V/Hz) drive control, AC motor
characteristics require that the voltage magnitude of the inverter's output to the motor be
adjusted to match the required load torque in a linear V/Hz relationship. For example, for 460
V, 60 Hz motors, this linear V/Hz relationship is 460/60 = 7.67 V/Hz. While suitable in wide-
ranging applications, V/Hz control is sub-optimal in high-performance applications involving
low speed or demanding, dynamic speed regulation, positioning, and reversing load
requirements. Some V/Hz control drives can also operate in quadratic V/Hz mode or can
even be programmed to suit special multi-point V/Hz paths.
The two other drive control platforms, vector control and direct torque control (DTC), adjust
the motor voltage magnitude, angle from reference, and frequency so as to precisely control
the motor's magnetic flux and mechanical torque.
Although space vector pulse-width modulation (SVPWM) is becoming increasingly popular,
sinusoidal PWM (SPWM) is the most straightforward method used to vary drives' motor
voltage (or current) and frequency. With SPWM control, quasi-sinusoidal, variable-pulse-
width output is constructed from intersections of a saw-toothed carrier signal with a
modulating sinusoidal signal which is variable in operating frequency as well as in voltage (or
current).
Operation of the motors above rated nameplate speed (base speed) is possible, but is limited
to conditions that do not require more power than the nameplate rating of the motor. This is
sometimes called "field weakening" and, for AC motors, means operating at less than rated
V/Hz and above rated nameplate speed. Permanent magnet synchronous motors have quite
limited field-weakening speed range due to the constant magnet flux linkage. Wound-rotor
synchronous motors and induction motors have much wider speed range. For example, a
100 HP, 460 V, 60 Hz, 1775 RPM (4-pole) induction motor supplied with 460 V, 75 Hz (6.134
V/Hz), would be limited to 60/75 = 80% torque at 125% speed (2218.75 RPM) = 100%
power. At higher speeds, the induction motor torque has to be limited further due to the
lowering of the breakaway torque of the motor. Thus, rated power can be typically produced
only up to 130-150% of the rated nameplate speed. Wound-rotor synchronous motors can be

run at even higher speeds. In rolling mill drives, often 200-300% of the base speed is used.
The mechanical strength of the rotor limits the maximum speed of the motor.
An embedded microprocessor governs the overall operation of the VFD controller. Basic
programming of the microprocessor is provided as user-inaccessible firmware. User
programming of display, variable, and function block parameters is provided to control,
protect, and monitor the VFD, motor, and driven equipment.
The basic drive controller can be configured to selectively include such optional power
components and accessories as follows:
 Connected upstream of converter -- circuit breaker or fuses, isolation contactor, EMC
filter, line reactor, passive filter
 Connected to DC link -- braking chopper, braking resistor
 Connected downstream of inverter—output reactor, sine wave filter, dV/dt filter.
SPWM carrier-sine input & 2-level PWM output
2.3- OPERATOR INTERFACE
The operator interface provides a means for an operator to start and stop the motor and
adjust the operating speed. Additional operator control functions might include reversing, and
switching between manual speed adjustment and automatic control from an external process
control signal. The operator interface often includes an alphanumeric display or indication
lights and meters to provide information about the operation of the drive. An operator
interface keypad and display unit is often provided on the front of the VFD controller as
shown in the photograph above. The keypad display can often be cable-connected and
mounted a short distance from the VFD controller. Most are also provided with input and
output (I/O) terminals for connecting push buttons, switches, and other operator interface
devices or control signals. A serial communications port is also often available to allow the
VFD to be configured, adjusted, monitored, and controlled using a computer.

123
2.4- DRIVE OPERATION
Referring to the accompanying chart, drive applications can be categorized as single-
quadrant, two-quadrant, or four-quadrant; the chart's four quadrants are defined as follows:
 Quadrant I - Driving or motoring, forward accelerating quadrant with positive speed
and torque
 Quadrant II - Generating or braking, forward braking-decelerating quadrant with
positive speed and negative torque
 Quadrant III - Driving or motoring, reverse accelerating quadrant with negative speed
and torque
 Quadrant IV - Generating or braking, reverse braking-decelerating quadrant with
negative speed and positive torque.
Most applications involve single-quadrant loads operating in quadrant I, such as in variable-
torque (e.g. centrifugal pumps or fans) and certain constant-torque (e.g. extruders) loads.
Certain applications involve two-quadrant loads operating in quadrant I and II where the
speed is positive but the torque changes polarity as in case of a fan decelerating faster than
natural mechanical losses. Some sources define two-quadrant drives as loads operating in
quadrants I and III where the speed and torque is same (positive or negative) polarity in both
directions.
Certain high-performance applications involve four-quadrant loads (Quadrants I to IV) where
the speed and torque can be in any direction such as in hoists, elevators, and hilly
conveyors. Regeneration can occur only in the drive's DC link bus when inverter voltage is
smaller in magnitude than the motor back-EMF and inverter voltage and back-EMF are the
same polarity.
In starting a motor, a VFD initially applies a low frequency and voltage, thus avoiding high
inrush current associated with direct-on-line starting. After the start of the VFD, the applied

frequency and voltage are increased at a controlled rate or ramped up to accelerate the load.
This starting method typically allows a motor to develop 150% of its rated torque while the
VFD is drawing less than 50% of its rated current from the mains in the low-speed range. A
VFD can be adjusted to produce a steady 150% starting torque from standstill right up to full
speed. However, motor cooling deteriorates and can result in overheating as speed
decreases such that prolonged low-speed operation with significant torque is not usually
possible without separately motorized fan ventilation.
With a VFD, the stopping sequence is just the opposite as the starting sequence. The
frequency and voltage applied to the motor are ramped down at a controlled rate. When the
frequency approaches zero, the motor is shut off. A small amount of braking torque is
available to help decelerate the load a little faster than it would stop if the motor were simply
switched off and allowed to coast. Additional braking torque can be obtained by adding a
braking circuit (resistor controlled by a transistor) to dissipate the braking energy. With a four-
quadrant rectifier (active front-end), the VFD is able to brake the load by applying a reverse
torque and injecting the energy back to the AC line.
3- BENEFITS
3.1- ENERGY SAVINGS
Many fixed-speed motor load applications that are supplied direct from AC line power can
save energy when they are operated at variable speed by means of VFD. Such energy cost
savings are especially pronounced in variable-torque centrifugal fan and pump applications,
where the load's torque and power vary with the square and cube, respectively, of the speed.
This change gives a large power reduction compared to fixed-speed operation for a relatively
small reduction in speed. For example, at 63% speed a motor load consumes only 25% of its
full-speed power. This reduction is in accordance with affinity laws that define the relationship
between various centrifugal load variables.
In the United States, an estimated 60-65% of electrical energy is used to supply motors, 75%
of which are variable-torque fan, pump, and compressor loads. Eighteen percent of the
energy used in the 40 million motors in the U.S. could be saved by efficient energy
improvement technologies such as VFDs.
Only about 3% of the total installed bases of AC motors are provided with AC drives.
However, it is estimated that drive technology is adopted in as many as 30-40% of all newly
installed motors.
An energy consumption breakdown of the global population of AC motor installations is as
shown in the following table:

125
3.2- CONTROL PERFORMANCE
AC drives are used to bring about process and quality improvements in industrial and
commercial applications' acceleration, flow, monitoring, pressure, speed, temperature,
tension, and torque.
Fixed-speed loads subject the motor to a high starting torque and to current surges that are
up to eight times the full-load current. AC drives instead gradually ramp the motor up to
operating speed to lessen mechanical and electrical stress, reducing maintenance and repair
costs, and extending the life of the motor and the driven equipment.
Variable-speed drives can also run a motor in specialized patterns to further minimize
mechanical and electrical stress. For example, an S-curve pattern can be applied to a
conveyor application for smoother deceleration and acceleration control, which reduces the
backlash that can occur when a conveyor is accelerating or decelerating.
Performance factors tending to favour the use of DC drives over AC drives include such
requirements as continuous operation at low speed, four-quadrant operation with
regeneration, frequent acceleration and deceleration routines, and need for the motor to be
protected for a hazardous area. The following table compares AC and DC drives according
to certain key parameters:

4- VFD TYPES AND RATINGS
4.1- GENERIC TOPOLOGIES
Topology of VSI drive Topology of CSI drive
Six-step drive waveforms Topology of direct matrix converter
AC drives can be classified according to the following generic topologies:
 Voltage-source inverter (VSI) drive topologies (see image): In a VSI drive, the DC
output of the diode-bridge converter stores energy in the capacitor bus to supply stiff
voltage input to the inverter. The vast majority of drives are VSI type with PWM
voltage output.
 Current-source inverter (CSI) drive topologies (see image): In a CSI drive, the DC
output of the SCR-bridge converter stores energy in series-Inductor connection to
supply stiff current input to the inverter. CSI drives can be operated with either PWM
or six-step waveform output.
 Six-step inverter drive topologies (see image) Now largely obsolete, six-step drives
can be either VSI or CSI type and are also referred to as variable-voltage inverter
drives, pulse-amplitude modulation (PAM) drives, square-wave drives or D.C.
chopper inverter drives. In a six-step drive, the DC output of the SCR-bridge

127
converter is smoothed via capacitor bus and series-reactor connection to supply via
Darlington Pair or IGBT inverter quasi-sinusoidal, six-step voltage or current input to
an induction motor.
 Load commutated inverter (LCI) drive topologies: In an LCI drive (a special CSI case),
the DC output of the SCR-bridge converter stores energy via DC link inductor circuit
to supply stiff quasi-sinusoidal six-step current output of a second SCR-bridge's
inverter and an over-excited synchronous machine.
 Cycloconverter or matrix converter (MC) topologies (see image): Cycloconverters and
MCs are AC-AC converters that have no intermediate DC link for energy storage. A
cycloconverter operates as a three-phase current source via three anti-parallel-
connected SCR-bridges in six-pulse configuration, each cycloconverter phase acting
selectively to convert fixed line frequency AC voltage to an alternating voltage at a
variable load frequency. MC drives are IGBT-based.
 Doubly fed slip recovery system topologies: A doubly fed slip recovery system feeds
rectified slip power to a smoothing reactor to supply power to the AC supply network
via an inverter, the speed of the motor being controlled by adjusting the DC current.
4.2- CONTROL PLATFORMS
Most drives use one or more of the following control platforms:
 PWM V/Hz scalar control
 PWM field-oriented control (FOC) or vector control
 Direct torque control (DTC).
4.3- LOAD TORQUE AND POWER CHARACTERISTICS
Variable-frequency drives are also categorized by the following load torque and power
characteristics:
 Variable torque, such as in centrifugal fan, pump, and blower applications
 Constant torque, such as in conveyor and positive-displacement pump applications
 Constant power, such as in machine tool and traction applications.
4.4- AVAILABLE POWER RATINGS
VFDs are available with voltage and current ratings covering a wide range of single-phase
and multi-phase AC motors. Low-voltage (LV) drives are designed to operate at output
voltages equal to or less than 690 V. While motor-application LV drives are available in
ratings of up to the order of 5 or 6 MW, economic considerations typically favor medium-
voltage (MV) drives with much lower power ratings. Different MV drive topologies (see Table
2) are configured in accordance with the voltage/current-combination ratings used in different
drive controllers' switching devices such that any given voltage rating is greater than or equal
to one to the following standard nominal motor voltage ratings: generally either 2.3/4.16 kV
(60 Hz) or 3.3/6.6 kV (50 Hz), with one thyristor manufacturer rated for up to 12 kV switching.
In some applications a step-up transformer is placed between a LV drive and a MV motor
load. MV drives are typically rated for motor applications greater than between about 375 kW
(500 HP) and 750 kW (1000 hp). MV drives have historically required considerably more
application design effort than required for LV drive applications. The power rating of MV

drives can reach 100 MW, a range of different drive topologies being involved for different
rating, performance, power quality, and reliability requirements.
4.5- DRIVES BY MACHINES AND DETAILED TOPOLOGIES
It is lastly useful to relate VFDs in terms of the following two classifications:
 In terms of various AC machines as shown in Table 1 below
 In terms of various detailed AC-AC converter topologies shown in Tables 2 and 3
below.
 BLDM PM trapezoid machine (Brushless DC electric motor)
 CSI Current source inverter
 GTO Gate turn-off thyristor
 IGBT Insulated gate bipolar transistor
 LCI Load commutated inverter
 LV Low voltage
 MV Medium voltage
 PAM Pulse-amplitude modulation
 PM Permanent magnet
 PMSM Permanent magnet synchronous generator
 PWM Pulse-width modulation
 SyRM Synchronous reluctance machine
 VRM Variable-reluctance machine
 VSI Voltage source inverter
 VVI Variable-voltage inverter
 WFSM Wound-field synchronous machine
 WRIM Wound-rotor induction motor

129
DIMER - AC-AC Vrms converter with fixed frequency

1- OBJECTIVE
 Drawing and electrical circuit according to the standards
2- THE MODULATION OF ENERGY:
The energy modulation allows from a fixed power source, to create a variable power source.
We can thus vary:
• The DC voltage
• the RMS Voltage;
• The DC current;
• The RMS current;
• The power
According to the type of power source, different modulators are distinguished:
AC Sources DC Sources
Fixed Voltage
Fixed Frequency
Fixed voltage
Rectifier
Inverter
Variable Voltage
Fixed Frequency
Variable Voltage
Controlled
Rectifier
Inverter
PWM Type
Dimmer
Chopper
Variable Voltage
Fixed Frequency
Controlled
Inverter
Fig 1 : Energy modulation
In the following part of this course, we will study the AC/AC energy modulation on
RESISTIVE load. The DIMMER and its command.

131
3- DIMMER PRINCIPLE
In a dimmer, a switch is used to "cut off" the supply voltage. This switch can be a contactor or
static switches.
3.1- BASIC DIAGRAM:
T
f
f
t
Sin
V
t
V
t
I
R
t
V
t
V
t
V
eff
e
ch
I
e
ch
1
2
)
(
2
)
(
)
(
)
(
)
(
)
( arg
arg















1.1. Type of Control
3.1.1-CONTROLLED BY TRAIN WAVE :
3.1.1.1- Controlled law :
The "Inter" switch is controlled according
to a TCycle cycle. We choose TCycle in
multiples of T
From 0 to t1 Inter is closed
=> )
(
)
(
arg t
v
t
V e
ch 
from t1 to TCycle Inter is opened
=> 0
)
(
arg 
t
V e
ch
The maximum power is :
R
V
P
eff
2
max 
The mean power in R is :
Cycle
moy
T
t
P
P 1
max 

Fig 2 : Principe de fonctionnement d’un GRADATEUR
2Veff
Vcharge(t)
t
TCycle
t1
t1
Veff
Vcharge eff
t
TCycle
t1
Pmax
Pmoy
t
TCycle
Fig 3 : Principle of wave train dimmer
Veff : Power supply rms voltage ;
 : network pulsation ;
f : fequency ;
T : Période de la fréquence du réseau
d'alimentation.
VI
V Vcharge
R
Icharge
Inter

Pmoy is linear and
function of teh ratio
Cycle
T
t1
1.1.1.1. Use of
wave train dimmer :
This type of control is mainly used in resistance heater control.
3.1.1.2- Design :
The witch can be :
• A contactor if the switching cycle TCycle is > 1 min.
• Thyristors otr Triac if teh switching time TCycle is < 1min. (Static contactor)
3.1.2-CONTROL BY PHASE ANGLE:
3.1.2.1- Controlled law :
 The switch is controlled on half period (T/2):
 From 0 to à t2 (0 to .t2) Inter is open => 0
)
(
arg 
t
V e
ch
 From t2 to T/2 (.t2 to ) Inter is closed => )
(
)
(
arg t
v
t
V e
ch 
 From T/2 to t2+T/2 (to .t2+T/2)) Inter is open => 0
)
(
arg 
t
V e
ch
 From t2+T/2 to T (.t2+T/2) to 2.) Inter is closed => )
(
)
(
arg t
v
t
V e
ch 
 In this case , Voltage and Current are not sinusoidal
Cycle
T
t1
1
0
Pmax
Pmoy
Fig 4 : Power in load controlled by wave train dimmer

133
3.1.2.2- Calculation :
DC Voltage: VDC = 0 ;
RMS Voltage :










2
)
2
(
1
arg
Sin
V
V eff
eeff
Ch
 is the controlled angle in radian ;
The RMS value of the current is:










2
)
2
(
1
arg
Sin
R
V
I
eff
eeff
Ch
The mean power in R is:
 
















2
2
1
2
Sin
R
V
P
eff
P is linear according to 
t2
2Veff
t

V(t)
2*
t2+T/2
2Veff
t
Vcharge(t) Icharge(t)
I Open I Close
2Veff/R

Fig 5 : Wave from of Curent and Voltge on a resistive load controlled by a phase angle dimmer

0
Pmax
P

Fig 6 : Power in the Resistive load controlled by dimmer.

1.1.2. Use of the dimmer :
This type of Dimmer is used mainly to control lighting.
3.1.3-DESIGN :
The switch is :
• Thyristors or Triac.
• This technology is also used to control the starting of Induction motor (Altisart)
3.2- MIXTE CONTROL :
This type of control is a mixt between
the two previous control types: Train
wave and Phase angle control
The Voltage RMS value will change
according to t1 and . The mean power is
function of the two parameters:
 
Cycle
eff
moy
T
t
Sin
R
V
P 1
2
2
2
1 
















This type of Dimmer allows a detailed
control pf the power.
4- TECHNICAL DESIGN :
Dimmer on the market are mostly designed with power electronics components. Dimmer are
built with Thyristor or Triac or power up to few KW in single-phase or three-phase systems.
4.1- SINGLE_PHASE DIMMER :
• Brand : EUROTHERM
• Voltage : 240 V 50 Hz ;
• Control Vdc 0 – 10 V = ;
• Control by phase angle;
• Current rating 16 A.
2Veff
Vcharge(t)
t
TCycle
t1

Fig 7 : Dimmer with mixte control

0
Pmax
P

t1/Tc
Fig 8 Power in load controlled by a mixted dimmer
Ph
N
Ph
N
Commande
Logique de
commande
Réseau Utilisation

135
4.2- THREE-PHASES DIMMER :
There are two types of dimmer:
4.2.1-TWO PAIRS OF THYRISTOR :
4.2.2-THREE PAIRS OF THYRISTORS :
Dimmer: AOIP 3020.
• Voltage : 400 V three-phases 50 Hz ;
• Current rating : 25 A
• Control by wave train, phase angle
control, mixt.
• Control Vdc (0-10V) or Keyboard
5- STATIC CONTACTOR :
The static blocks (or static relays) have the same structure as the dimmers above. Only the
type of order is different. Here we have a command by wave train.
6- NOTIONS OF HARMONIC DISTURBANCE AND
ELECTROMAGNETIC COMPATIBILITY:
6.1- HARMONIC DISTURBANCE:
Devices containing static switches allow the rms and dc values of voltages and currents to be
modified. This type of assembly absorbs currents whose sinusoidal shape is altered or totally
modified (see phase angle dimmer) on the network. This results in a signal that is a
Ph 1
Control
Commande
logic
Network Use
Ph 2
Ph 3
Ph 1
Ph 2
Ph 3
Ph 1
Control
Control
Logic
Network Use
Ph 2
Ph 3
Ph 1
Ph 2
Ph 3

superposition of sinusoids with multiple frequencies of the frequency of the network (these
are the Harmonics).
This type of current causes disturbances of the network (PLN in particular). To limit the
disturbances, the standards fixed a maximum value of Harmonic Distortion ie a
THDmaximum = 8% for current and voltage in LV.
6.2- EFFECT OF BAD THD :
Le tableau suivant définit les conséquences sur les appareils d'un mauvais THD.
Equipment Effect of the harmonics
Motors
Induction, Synchronous motor, Generator
Additional heating (Joule effect) in the stator windings. Oscillatory couples.
Increase in noise
Transformer
Additional losses in the iron (by Foucault currents) and in the windings (by
Joule effect). Risk of saturation in the presence of even harmonics.
Cable
Increased losses especially in the neutral cable where are added the
harmonics of rank 3 and multiples of 3. Additional dielectric losses.
Power electronics
(Thyristor rectifier bridges, transistors,
etc.).
Functional disorders related to the waveform (switching, synchronization).
Power capacitors Additional dielectric losses leading to premature aging of the capacitors
Computers
Malfunction related to pulsating couples of
magnetic media drive motors
Protective devices
(Fuses, magneto-thermic circuit breakers
...)
Inopportune operation
Energy meter Measurement errors
TV IMAGE distortion
Discharge lamps Risk of wobbling under the effect of the harmonic of rank 2
6.3- ELECTROMAGNETIC COMPATIBILITY (EMC) :
Any electronic switch, switching, emits electromagnetic radiation. It causes dissemination in
the environment of a radio wave. This wave has the effect of disrupting the operation of
surrounding devices. (TP with Radio). European Directive 89/336 / EEC of 3 March 1989 set
the EMC standards before placing a device on the market.
7- TO SUM UP
A dimmer with resistive load :
Type of command Use Advantages Disadventages
Phase angle control
Lighting,
Heating
The power is linear to the
control
Disturbance on the network.
(THD <> 0)
Train d'onde Resistive heating
The power is linear to the
control
No harmonics disturbances
(THD  0)
Power not linear

137
8- DIMENSIONING OF A STATIC SWITCH IN A DIMMER:
The exercise is about dimmer of the lighting system of a performance room. It feeds side ramps with an installed
power of 400 W (2 * 2 * 100W). The power supply is 230 V 50 Hz. Control by phase angle.
• Draw the power diagram of the side ramps.
• For  = 0,  / 2, , draw on the response documents page 10/11 the waveforms of:
o The voltage at the terminals of the lamps VL (t);
o The voltage across the Thyristors VTH (t);
o The current flowing in the lamps IL (t);
o The current in a thyristor ITH1 (t).
• For = 0 determine using Annex 1, the maximum value of the average and effective
current passing through a thyristor.
• For  =  determine using Annex 1, the maximum value of the voltage across a
thyristor.
• What are the characteristics necessary for the choice of a thyristor?
• Using the previous calculations, give these values.
• Choose the appropriate thyristor for mounting in the document Annex 2.
• To give for the thyristor chooses the characteristics necessary for the priming of the
thyristor.

8.1- RESPONSE DOCUMENTS:
2Veff
t
V(t)
t
VL(t) IL(t)
t
VTH(t) ITH1(t)
Doc. Réponse 1 :  = 0
2Veff
t
V(t)
t
VL(t) IL(t)
t
VTH(t) ITH1(t)
Doc. Réponse 2 :  = /2
2Veff
t
V(t)
t
VL(t) IL(t)
t
VTH(t) ITH1(t)
Doc. Réponse 3 :  = 

139
8.2- ANNEXES :
Annexe 1 : Formules de calcul de valeur efficace et de valeur moyenne

MANUAL CONTROL

141
MANUAL CONTROL
1- CONTROL OF A SINGLE CONTACTOR
Features
The switch is maintained in the closed position by a latching device.
When the supply is interrupted, contactor KM1 opens and the motor which drives the
machine stops. When the supply returns, since the switch contact is still closed, the contactor
closes again and the machine starts without the operator being warned. This type of control
is only admissible for non-dangerous machine applications (pumps, air conditioning...) and
normally operates without special supervision. In all other cases, use a manual spring return
push-button control.
Operation
 Closing of contactor KM1 by contact (13-14) of switch S1.
1.1- CONTROL BY A SPRING RETURN PUSH-BUTTON
Features
 Spring return push-button.
 The contactor coil is energised only while the button is depressed.
Operation
 Closing of contactor KM1 by contact (13-14) of push-button S1.
1.2- LOCAL CONTROL BY BUTTONS ON STARTER ENCLOSURE
Features
 Push-buttons I and O mounted on the enclosure.
 One or more remote control stations can be added.
Operation
Closing of contactor KM1 by pressing push-button I.
 Hold-in by contact (13-14).
 Stop by pressing push-button O which acts mechanically on the contact (95-96)
incorporated on the thermal overload relay.

1.3- REMOTE CONTROL BY 2 SPRING RETURN PUSH-BUTTONS
Features
When the supply is interrupted the contactor opens, S2 must then be pressed in order to
close the contactor again. One or several remote control stations can be incorporated.
Operation
 Closing of contactor KM1 by contact (13-14) of push-button S2.
 Hold-in by contact (13-14) of KM1.
 Stop by contact (21-22) of push-button S1.
1.4- REMOTE CONTROL BY SEVERAL SPRING RETURN PUSH-BUTTONS
Features
Possibility of remote control from several points.
Operation
 Closing of contactor KM1 by either of the start buttons S2-S4 connected in parallel.
 Hold-in by contact (13-14).
 Stop by either of the stop buttons S1-S3 connected in series.
1.5- REMOTE CONTROL, “RUN-INCH”
Features
Possibility of inching for adjustment (conveyor belt), or for the setting up of a machine (lathe,
printing machine), or for the positioning of a workpiece.
Operation
 Switch S3 in “run” position :
o Contact (13-14) of switch closed.
o Closing of contactor KM1 by contact (13-14) of the start push-button S2.
o Hold-in by contact (13-14) of KM1.

143
MANUAL CONTROL
o Stop by contact (21-22) of push-button S1.
 Switch S3 in “inch” position :
o Contact (13-14) of switch open.
o Closing of contactor KM1 by contact (13-14) of the start push-button S2, but
opening of KM1 when push-button is released.
2- CONTROL OF TWO CONTACTORS
2.1- CONTROL BY SWITCH
Features
Possibility of reversing the direction of a motor.
Starting and stopping are controlled by the operator.
Mechanical and electrical interlocking between the two contactors.
Operation
 Contact (13-14) of switch S1 closed.
o Closing of contactor KM1 if KM2 is open.
o Opening of contact (21-22) of KM1 (electrical interlock with KM2).
o Stop by action of switch S1.
o Stop by action of switch S1.
2.2- CONTROL BY SPRING RETURN PUSH-BUTTONS
Features
Possibility of reversing the direction of a motor.

Operation
 Forward :
o Press push-button S2.
o Hold-in of KM1 (13-14).
o Stop by push-button S1.
 Reverse :
o Press push-button S3.
o Stop by push-button S1.

145
VISUAL SIGNALLING
VISUAL SIGNALLING

1- “SUPPLY ON” LAMP
A pilot light indicates that the supply is switched on to the installation, the power being
switched on generally by means of a fused isolator placed on the supply side.
Operation
 Isolator Q1 is closed manually.
 The pilot light is energised by Q1 (13-14).
2- “ON” LAMP
The pilot light indicates the closing of a contactor.
Operation
 Closing of KM1.
 Pilot light is energised by KM1 (53-54).
3- “OFF” LAMP
Contrary to the previous example, the opening of the contactor is indicated.
Operation
 Pilot light is energised.
 Closing of KM1.
 Pilot light is extinguished by KM1 (61-62).

147
COMBINED AUTOMATIC AND MANUAL CONTROL

1- CONTROL BY SELECTOR SWITCH AND LIMIT SWITCHES
Features
Possibility of reversing the direction of the motor.
Automatic stop at the end of travel.
Operation
o Closing of contactor KM1 if contact of limit switch S2 closed and contactor
KM2 open.
o Stop by action of switch S1 or by limit switch S2.
 Closing of contactor KM2 if contact of limit switch S3 closed and contactor KM1 open.
 Opening of contact (21-22) of KM2 (electrical interlock with KM1).
 Stop by action of switch S1 or by limit switch S3.
2- CONTROL BY SPRING RETURN PUSH-BUTTONS AND LIMIT
SWITCHES
Features
Identical to those described opposite.
Operation
 Forward: press push-button S2.
KM2 open.
o Stop by push-button S1 or by limit switch S4.
 Reverse: press push-button S3.
KM1 open.
o Stop by push-button S1 or by limit switch S5.

149

STARTING OF SQUIRREL CAGE MOTORS

151
1- DIRECT-ON-LINE STARTING OF A 3-PHASE MOTOR, WITH OR
WITHOUT FUSIBLE OFF-LOAD ISOLATOR
1.1- LOCAL CONTROL
The association of a fusible off-load isolator, a contactor and a thermal overload relay in an
enclosure protects against short circuits and overloads.
Controls
 Start: manual, by push-button.
 Stop: manual, by push-button; automatic when the thermal overload relay trips, when
there is a supply voltage failure, or a fuse blows (starter fitted with a fused isolator
and a device to protect against single-phase operation).
 Reset: manual, after tripping of the overload.
 Signalling of tripping: by auxiliary contact (97-98) mounted on 3-pole thermal overload
relay.
Protection
 By a fused isolator, against short-circuits.
 By a 3-pole thermal overload relay, against small and prolonged overloads, and
phase failure.
Power circuit operation
 Manual closing of isolator Q1. Closing of KM1.
 Features: Isolator Q1 is rated for the motor FLC (full load current). Contactor KM1 is
rated for the motor FLC and utilisation category. Overload F1 is rated for the motor
FLC.
Control circuit operation
 Press I (17-18); Closing of KM1. Hold-in of KM1 (13-14).
 Stop : by pressing O, or by tripping of overload relay F1 (95-96)
1.2- LOCAL AND REMOTE CONTROL
The starter is equipped with local control, but where access is difficult, remote controls can
be added.
Controls
 Start: manual, local control by push-button; manual, remote, by push-button.
 Stop: manual, local control by push-button; manual, remote, by push-button;
automatic: identical to local control.
 Reset: manual, after tripping of the overload relay, possibility of remote reset by
addition of the appropriate add-on block on the overload relay.
 Signalling of tripping by the auxiliary contact (97-98) mounted on the 3-pole thermal
overload relay; on starting by the pilot light on the remote control station.
Protection :
 identical to local control.

1.3- POWER CIRCUIT OPERATION :
 identical to local control.
 Press I (17-18) or I (13-14). Closing of KM1.
 Hold-in of KM1 (13-14). Stop: by pressing O (21-22) or by tripping of thermal overload
relay F1 (95-96).
2- DIRECT-ON-LINE REVERSING STARTER
2.1- LOCAL CONTROL
 Manual closing of isolator Q1.
 Closing of KM1 (forward) or KM2 (reverse).
Features :
 Isolator Q1 is rated for the motor FLC (full load current).
 Contactors KM1 and KM2 are rated for the motor FLC and utilisation category.
Overload F1 is rated for the motor FLC.
 Mechanical and electrical interlocks between KM1 and KM2.
 Press push-button I or II.
 Either KM1 or KM2 closes.
 Hold-in of KM1 or KM2 (13-14).
 Electrical interlocking of KM1 by KM2 or KM2 by KM1 (61-62).
 Manual stop by pressing R.

153
3- STAR-DELTA STARTER WITH FUSED ISOLATOR
3.1- WITH TIME DELAY CONTACT BLOCK ON CONTACTOR KM2
 Manual closing of isolator Q1.
 KM1 closes to create the star connection.
 KM2 closes to feed the main motor current.
 KM1 opens the star connection.
 KM3 closes to create the delta loop.
 KM2 and KM1 close together to start the motor in “star”, after a short period KM1
opens and KM3 closes to finish the starting sequence with the motor finally
connected in “delta”.
Features :
The motor windings, when connected in delta, must be rated for the main supply voltage.
 Isolator Q1 is rated for the motor FLC (full load current)
 Overload F2 is rated for the motor FLC / √ 3
 Contactor KM1 is rated for the motor FLC / 3
 Contactors KM2 and KM3 are rated for the motor FLC / √ 3
 Press push-button S2, KM1 closes.
 A contact on KM1 will close KM2 (53-54).

 A contact on KM2 will hold-in KM1 and KM2 (13-14).
 After a short delay KM1 will open and KM3 will close (controlled by timed contact 67-
68 on KM2 and contact 21-22 on KM1).
 The drive may be stopped by pressing push-button S1.
Features :
 Electrical interlocking between KM1 and KM3.
 The LA2-D time-delay contact block incorporates a 40 ms time delay between the
opening of its N/C contact and the closing of its N/O contact. This eliminates any risk
of a short-circuit during the star-delta transition, which could be caused by the arcing
of the contactors.

155
B. Practical Teaching Contents

DOL TWO DIRECTION CONTROLLED BY INTEGRATED SYSTEM
TOT - Training of Trainer Code: TOT-M03-PA-006-
TR_004_Ver-00
Title:
DOL two direction controlled by integrated
system
# 004
Module: M4-Industrial Installation Doc: TR - Trainee
Topic: 006 - Industrial wiring
Type of Activity: PA -
Practical Activity
Equipment
:
C03 - Industrial devices for wiring.
Main
Objective
cpt.3-1 - Drawing and electrical circuit according to the standards
cpt.3-3 - Implement electrical wiring according to the standards
cpt.3-4 - Select the equipment in order to design an electrical circuit
cpt.3-5 - Establish the list of required equipment in order to make the electrical wiring of
a building
cpt.3-7 - Perform the commissioning of electrical circuit
Objectives The trainee will be able to :
Duration: 4:0
resources: Docs
- A4 - TeSys U_P_EN.pdf
- A4 - TeSys U_P_EN-Wiring.pdf
- TeSys U_1629984_01A55.pdf
- TeSys U_1639084_01A55.pdf
- TeSys U_163884301A05-10.pdf
Standards :
-

157
1- LIST OF EQUIPMENT
 Wiring Bench
 Power supply
o Connectors blocs
o 1 MCB C10 4P and 1 RCD 30mA 4 P)
o 1 MCB C4
o 1 MCB C2
o 1 transformer 230-400V:24V
 Tool set
 Tesys U pack
o Power base LUB120
o Auxiliary contacts LUA1C20
o Auxiliary contacts LUFN11
o Control Unit LUCA05B
o Reverse bloc LU2MBOB
o Connector block LU9M1
o Pre-wiring block LU9MR1C
 1 Box 3 Push buttons XAL D311
 1 Box 8 holes for push buttons and pilot lamps XAP A2108
 2 Push Buttons with 1 NO and 1 NC each
 1 Push button with 1 NC
 1 Pilot lamp Red
 1 pilot lamp Yellow
 1 pilot lamp Green
 Set of connectors
 Set of wires
 Set of number
 Computer + QElectrotech Software
Symbols:
Work to be performed Information / Tip
Teacher/Professor required Danger

2- PREAMBLE
The Direct on line starter is to control an induction motor. The control circuit is usually
composes with Switch Disconnector, Fuses or Magnetic Relay, Contactors and overload
relay. All of these devices have the target to control the power supply of the motor and to
protect the equipment against overload and short circuits. For a 2 direction control, additional
equipment is required.
3- TASK 1
With the help of the software QElectrotech, design, according to the standard, a DOL 2
direction circuit to control an Induction Motor.
The devices used must be
 Q1: Switch disconnector with Magnetic relay
 KM1: Contactor (Forward)
 KM2: Contactor (Reverse)
 F1: Overload Relay
 S0: Emergency Stop Button
 S1: Stop Push Button
 S2: Forward Push Button
 S3: Reverse Push Button
Q 1. What is the function of each device?
Q 2. How many wires do you need to do the wiring?
4- TASK 2
Manufacturers of industrial devices have created new integrated equipment to control
motors. Schneider Electric created the Tesys U system to do that.
By studying the recourse document “A4 - TeSys U_P_EN.pdf” pages A4/2 to A4/9, answer
the following questions:
Q 3. What are the functions included in the Tesys U system?
Q 4. With the equipment at your disposal, indicate the name, reference and function of
each part.
With the help of the resource document “A4 - TeSys U_P_EN-Wiring.pdf”, draw on
QElectrotech the DOL 2 direction circuit.
Q 5. How many wires do you need to do the wiring?
Q 6. Is this integrated system will add advantages on the wiring to compare with the
traditional wiring?

159
5- TASK 3
Q 7. Complete your DOL 2D with Tesys U system diagram by adding the following pilot
lamps:
 Forward direction – Yellow pilot lamp
 Reverse direction – Green pilot lamp
 Overload/Short Circuit – Red Pilot lamp.
Q 8. List all devices, equipment you need to perform the wiring of the DOL 2D with
Tesys U System.
Q 9. Collect your equipment and perform the wiring.
Q 10. With the Master trainer and according to the security standards, perform the
commissioning and test your equipment.
Q 11. If there is malfunction, find and repair the fault. Test again.
Don’t remove your equipment, you will use it for the next exercise

SOFT STARTER
TR_005_Ver-00
Title: Soft Starter # 005
Practical Activity
Equipment
:
Main
Objective
cpt.3-3 - Implement electrical wiring according to the standards
cpt.3-5 - Establish the list of required equipment in order to make the electrical wiring of
a building
Duration: 1:0
resources: Docs
-
Standards :
-

161
SOFT STARTER
 Wiring Bench
 Power supply
o Connectors blocs
o 1 MCB C4
o 1 MCB C2
 Tool set
 Tesys U pack
o Power base LUB120
o Auxiliary contacts LUA1C20
o Auxiliary contacts LUFN11
o Control Unit LUCA05B
o Reverse bloc LU2MBOB
o Connector block LU9M1
o Pre-wiring block LU9MR1C
 Soft Starter Altisart ATS01N206QN
 Circuit Breaker GV2ME08
 2 Push Buttons with 1 NO and 1 NC each
 2 Push button with 1 NC
 1 push button 1 NO
 1 switch 1NO
 Set of wires
 Set of number
Symbols:

2- PREAMBLE
The Direct on line starter for Induction Motor produces a huge demand of current. Usually the
starting current is 7 to 10 times the rating current of the motor. This situation can be an issue
for motor with large Power. To solve this issue, starters have been designed such as Star-
Delta, Rotor or Stator starters. The aim is to reduce the starting current.
The new power electronic components have allowed the design of “Electronic Starter”. The
Altistart is one of them. This device will help to control the starting current of the Induction
Motor.
It is composed of dimer that will control the voltage across the motor coil and consequently
the current. But this as a drawback! The toque will be affected and the starting torque will be
less than the DOL one. To fix it, an initial voltage and a bust voltage can be controlled by the
Altisart.
3- TASK 1
By using the technical documents about the Altistart (DIA2ED2140603EN %28web%29.pdf
and ATS01_IS_ATS01N2_1624686_04.pdf) available on the Moodle platform, answer the
following questions:
Q 1. What are the functions of the 3 selector on the altistart?
Q 2. How can we control the start and Stop of the motor?
Q 3. What is the rating of the Altistart in your possession?
4- TAKS 2
With the help of the documents above:
Q 4. Add on your previous wiring diagram the soft starter Altistart. The control of the
starting will be done directly by connecting the terminal “LI2” with the terminal “LI+” of
the Altistart. (You must use the previous wiring (DOL FR/RV with TeSys U system)
Q 5. After validation of the Master Trainer, apply the modifications to your wiring.
Q 6. Perform the commissioning and test your system.
Q 7. Are the start and Stop according to the time diagram given on the data instruction
sheet? (ATS01_IS_ATS01N2_1624686_04.pdf)
Q 8. By using an Oscilloscope and a voltmeter, Observe the voltage on the motor coil.
Describe the evolution of the voltage and the consequences on the motor functioning.
5- TASK 3
Q 9. Modify your installation to control the start and stop of you motor by using a switch.

163
SOFT STARTER
6- TASK 4
Q 12. Modify you wiring to control the Start and Stop with Push Buttons.
Q 15. Connect the “BOOST” input to the “LI+” terminal.
Q 16. Test your system.
Q 17. What is the effect of the “BOOST” Function?
Remove all wires and components from you mesh (Expect Power
supply). Clean you working place.

INDUCTION MOTOR CONTROLLED BY VSD
TR_0006_Ver-00
Title: Induction Motor controlled by VSD # 0006
Practical Activity
Equipment
:
Main
Objective
cpt.3-8 - Perform electrical measurement according to the safety and security rules
Cliquez ici pour taper du texte.
Duration: 5:0
resources: Docs
-
Standards :
-

165
 Wiring Bench
 Power supply
o Connectors blocs
o 1 MCB C4
o 1 MCB C2
 Tool set
 1 Circuit Breaker GV2ME08
 1 Contactor LD09
 1 VSD Altivar 312
 1 Potentiometer
 1 Push Buttons with 1 NO
 1 Push Buttons with 1 NC
 1 Emergency Stop Button with 1 NC
 1 Selector Switch 3 position with 2 NO
 Set of wires
 Set of number
Symbols:

2- PREAMBLE
To control the starting current of an Induction motor, we can us a soft starter, but if we want
to control more efficiently the starting and the running of the motor, we can use a “Variable
Speed Drive” or VSD.
You will perform in this activity the wiring and the configuration of a VSD to control the speed
of an induction motor.
3- STUDY OF VSD
With the help of the documents
 “ATV312_Getting_Started_EN_S1A10942_04.pdf” page 2
 “ATV12_user_manual_EN.pdf”, pages 17 to 27
Q 1. Identify the name of the terminals used for the power supply and to connect the
motor.
Q 2. Identify the inputs used to control the motor. (in 2 wires configuration)
a. What input control the Forward, the Reverse direction?
b. Those inputs will be controlled by Switch or Push button?
Q 3. Witch inputs control the speed reference?
a. With what component, the speed reference is setting up?
Q 4. What is the function of the terminal R1A, R1B, R1C?
Q 5. The supply of the VSD will be done with a “Watch Dog” circuit. A Watch Dog circuit
is a circuit that monitor the security of a system. The most common is a DOL style
circuit. It contains at least 1 Emergency Stop Button, a Start push button (Power Up),
a Stop push Button (Power down) and a contactor. The contact “VSD ready is placed
in series with the contactor’s memory contact. With the help of the previous
questions, design the electrical circuit to control an Induction Motor through a VSD
with the following components:
 Q1: Main Circuit Breaker
 KM1: Watch Dog Contactor
 S0: Emergency Stop Button
 S1: Power down push button
 S2: Power up push button
 VSD: Variable Speed Driver ATV312
 S10: Turn Switch 3 positions (2 NO contacts) for Forward/Reverse control
 P1: 10 K potentiometer to control the speed reference.
 Connectors & terminals.
Q 6. After validation from the Master Trainer, collect the equipment and perform the
wiring.
Q 7. Perform the commissioning of your wiring.

167
4- VSD’S CONFIGURATION
Q 8. With the help of the documents “ATV12_user_manual_EN.pdf”, page 45, describe
the procedure to reset the VSD to its factory settings (parameter set).
Q 9. Perform the factory parameter reset on your VSD.
Q 10. After a rest to factory setting, the VSD needs to be configured with our application.
a. With the help of the page 29, give the function of the following parameters:
bFr, Uns, LSP, HSP, Ith.
b. Adjust the parameter above to the application and motor.
Q 11. After agreement of the Master Trainer, perform the test and check that the motor’s
speed will follow the speed reference given by the potentiometer.
Q 12. What is the function of ACC and DEC parameter?
a. Verify your affirmation by testing different values.
5- CONTROL BY 3 WIRES CONFIGURATION.
Q 13. With the help of the previous document, modify the wiring of your installation to
control the VSD and its motor with the 3 Wires configuration.
Q 14. Lock up in the documentation the parameter to adjust to be able to control the VSD
with the 3 wires configuration.
Q 15. After agreement of the Master Trainer, test your system.
6- MEASUREMENTS
Q 1. By using an oscilloscope and its probes (current and voltage), visualize the current
and the voltage across a motor coil.
a. What ids the shape of the current?
b. What is the effect off a torque change?
c. What is the shape of the voltage?
d. What is the effect of a speed reference change?
Q 2. Visualize the current and the voltage on the input power of the VSD.
a. What is the shape of the Voltage?
b. What is the shape of the current?
c. What is the effect of the torque change?

169
C. Annexes & Resources

171
1- RESOURCES, FILES, PDF, SOFTWARE, .. AVALIABLE ON THE
RESOURCE FOLDER.
Resources
IEC60617 Symbols.pdf
PriceList_General_2019_Feb.pdf
0.Resources Lectures
02. PLC.pptx
03. HMI - Magelis XGU.pdf
04. SCADA.pptx
Instalasi Citect SCADA 2016.pdf
1.Software
QElecrrotech Diagrams
atv320.pdf
ATV320.qet
dol.pdf
DOL.qet
QElecrrotech
Doc
QElectroTech create a simple symbol.mp4
QElectroTech reports new tags for conductors.mp4
QElectroTech rules numbering.mp4
QElectroTech Show how to use report folio, cross
references,.mp4
QElectroTech Tutorial 01 Introduction.mp4
Team QElectroTech - YouTube.URL
Welcome to QElectroTech! 0.4 finale_QElectroTech
2015 documentation.URL
Installer_QElectroTech-0.60_x86_64-win64+svn5255-1.exe
QElectroTech Downloads.URL
QElectroTech Welcome, presentation.URL
qelectrotech-0.60+svn5255-x86-win32-readytouse.zip
So Machine
E Learning SoMachine.zip
M221 SoMachineBasic_V1.6SP1_build62140.exe
SoMachine Basic Operating Guide.pdf
SoMachineBasic_V1.6_SP2_build62620.exe
Vijeo
EcoStruxure Machine ExpertProgramming Guide.pdf
EcoStruxureTM Machine Expert - Basic.pdf
HMI VijeoDesignerBasic1.1.exe
2.IA-PLC-HMI Kit
ABL1- Power Supply
Phaseo ABL1_ABL1REM24042.pdf
Phaseo ABLA1_User Guide.pdf
Ethernet - TCSESU053FN0
Industrial Ethernet_Catalog 2019.pdf

TCSESU053FN0.pdf
TCSESU053FN0_User Guide.pdf
Harmony© XB7
Harmony XB7_XB7EV03MP.pdf
Harmony XB7_XB7NA31.pdf
Harmony XB7_XB7NA42.pdf
Harmony XB7_XB7ND21.pdf
Harmony© XB7_Catalog 2019.pdf
Instruction_Sheet_Harmony_XB7-1.pdf
Instruction_Sheet_Harmony_XB7.pdf
HMI - HMIGXU3512
Brochure - HMIGXU (2015).pdf
Catalogue - HMIGXU (2015).pdf
Easy Harmony GXU_HMIGXU3512.pdf
EAV83639_02.pdf
HMI_Catalog 2019.pdf
M221-Module MT3TI4-TM3AQ4-Analog Inputs-Outputs
Modicon TM3_TM3AQ4.pdf
Modicon TM3_TM3TI4.pdf
Modicon_TM3--_TM3T--_Installation guide.pdf
Modicon_TM3_Expansion Modules Configuration.pdf
Modicon_TM3_I-O expansion modules for Modicon-2019.pdf
M221-PLC
M221 Advanced Functions.pdf
M221 Brochure.pdf
M221 Catalog 2015.pdf
M221 CPU Hardware Guide.pdf
M221 Generic Function.pdf
M221 Logic Controler-Hardware Guide.pdf
M221 Modbus Master Example.pdf
M221 Operator Display.pdf
2M221 Programming Guide.pdf
M221 SMS Example.pdf
M221-TM221CE40R
M221_Catalog_2019.pdf
PLC - Modicon M221_TM221CE40R.pdf
M221 _Programing Guide.pdf
MCB - A9F04206
DIN Rail modular devices_A9F74206.pdf
Instruction Sheet iC60N.pdf
3.IA-Sensor Kit
ABL1- Power Supply
Phaseo ABL1_ABL1REM24042.pdf
Phaseo ABLA1_User Guide.pdf
Harmony© XB7
Harmony XB7_XB7EV06BP.pdf
Harmony© XB7_Catalogue.pdf
sensors
163439701A55.pdf
BBV13273.pdf
Opto-electronic rotary encoders_instruction sheet.pdf
OsiSense XCC_XCC1406PR01K.pdf
OsiSense XC_XCMD2110L1.pdf

173
OsiSense XC_XCMD2115L1.pdf
OsiSense XS & XT_XS112BLPAL2.pdf
OsiSense XS & XT_XT118B1PAL2.pdf
OsiSense XU_XUK1APANL2.pdf
OsiSense XU_XUK2AKSNL2T.pdf
OsiSense XU_XUK2APBNL2R.pdf
OsiSense XU_XUK5APANL2.pdf
XU_XUZC50.pdf
OsiSense XU_XZCP1241L5.pdf
OsiSense XX_XX930A1A1M12.pdf
XT1 _ Instruction sheet.pdf
XX930A1A1M12_ Instruction sheet.pdf
_Catalogue_Capacitive Proximity Sensor.pdf
_Catalogue_Inductive Proximity Sensor.pdf
_Catalogue_Limit switches.pdf
_Catalogue_Opto-electronic rotary encoders.pdf
_Catalogue_Ultrasonic sensors.pdf
4.Other Ressources
ATV320
ATV320_ATV_Logic_Manual_EN_NVE71954_01.pdf
ATV320_Catalogue.pdf
ATV320_Getting_Started_EN_NVE21763_02.pdf
ATV320_installation_manual_EN_NVE41289_04.pdf
ATV320_Programming_Manual_EN_NVE41295_03.pdf
ATV320_Safety_Function_manual_EN_NVE50467_02.pdf
TeSys U
1629984_01A55.pdf
163884301A05-10.pdf
1639084_01A55.pdf
A4 - TeSys U_P_EN-Wiring.pdf
A4 - TeSys U_P_EN.pdf

Ver.1.1 - Confidential Property of CoE EARE
INONESIAN - FRENCH – SCHNEIDER ELECTRIC
Centre of Excellence for
Electricity, Automation and Renewable Energy
@PPPPTK BMTI, Jalan Pesantren KM.2 Kel. Cibabat, Cimahi Utara, Cimahi 40513, Jawa Barat
Phone : +62 (0)22 665-2326 x142
In Partnership with:
THE MINISTRY OF EDUCATION – FRENCH REPUBLIC
THE MINISTRY OF EDUCATION AND CULTURE – REPUBLIC OF INDONESIA
SCHNEIDER ELECTRIC FOUNDATION
PT SCHNEIDER ELECTRIC INDONESIA

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