Design of three phase relay circuit electrical trainer having fault inserting and troubleshooting to provide industrial exposure

Project Title

Design of three phase relay circuit electrical trainer having fault inserting and troubleshooting to provide industrial exposure

Project Area of Specialization Electrical/Electronic EngineeringProject Summary

This Trainer (Design of three Phase Relay Circuit Electrical Trainer Having Faulty Inserting & Troubleshooting To provide industrial Exposure) provides a course on the operation and trouble shooting for electrical control circuits. It has a unique control training capabilities with a fault insertion system which is useful as a teaching aid in fault-finding or troubleshooting the electrical installation. Connection between the components are made by using stack-cable 4 mm test leads, which plugs into 4 mm color-coded heavy-duty captive-head binding post. Fault simulator switches installed at special closed box which placed at back of trainer.

The unit consists of various real industrial components that are common to electrical installation and control circuits. These components are mounted onto a training display board and their electrical components are bought out 4 mm terminals. During the student exercises connection are made by test leads, which gives the student through the experiment and provides the necessary theoretical background to allow student successfully to complete the educational objectives. The topic include: varieties of contactor, thermal overload, typical of connections and wiring diagrams motor control for star connection, motor control for delta connections and wiring diagrams, motor control for star delta connection, fault finding and trouble shooting.

Project Objectives

1. Familiarization of circuit protection devices..
2. Install circuit of direct on line starter (DOL) circuit
3. Explain work principle and trouble shooting of regulated cam switch.
4. Install circuit of “start-stop three phase induction motor circuit completed by control safety devices.
5. Explain work principle and trouble shooting of emergency switch.
6. Installation the thermal overload in power wiring and control wiring.
7. Testing and setting of thermal overload.
8. Explain the thermal overload work principle and trouble shooting.
9. Install check and differentiate power lamp indicators and control lamp indicators
10. Do troubleshooting of lamp indicators.
11. Explain work principle and trouble shooting of push button.
12. Install and operate the forward and reverse of three phase induction motor circuit by using   magnetic contactors.
13. Explain the magnetic contactor work principle and trouble shooting.
14. Explain the effect of mechanical interlocking failure of magnetic contactors.
15. Explain the function, work principle of time delay relay and magnetic contactors.
16. Install circuit of three phase induction motor by using time delay relay and magnetic contactors.
17. Analyze and trouble shooting of starting failure by using time delay relay and magnetic contactors.
18. Install circuit of automatic star delta motor starting by using magnetic contactors and time delay relay.
19. Analyze and trouble shooting of automatic star delta motor starting failure.
20. Familiarization of circuit protection devices..
21. Install circuit of direct on line starter (DOL) circuit
22. Explain work principle and trouble shooting of regulated cam switch.
23. Install circuit of “start-stop three phase induction motor circuit completed by control safety devices.
24. Explain work principle and trouble shooting of emergency switch.
25. Installation the thermal overload in power wiring and control wiring.
26. Testing and setting of thermal overload.
27. Explain the thermal overload work principle and trouble shooting.
28. Install check and differentiate power lamp indicators and control lamp indicators
29. Do troubleshooting of lamp indicators.
30. Explain work principle and trouble shooting of push button.
31. Install and operate the forward and reverse of three phase induction motor circuit by using   magnetic contactors.
32. Explain the magnetic contactor work principle and trouble shooting.
33. Explain the effect of mechanical interlocking failure of magnetic contactors.
34. Explain the function, work principle of time delay relay and magnetic contactors.
35. Install circuit of three phase induction motor by using time delay relay and magnetic contactors.
36. Analyze and trouble shooting of starting failure by using time delay relay and magnetic contactors.
37. Install circuit of automatic star delta motor starting by using magnetic contactors and time delay relay.
38. Analyze and trouble shooting of automatic star delta motor starting failure.

Project Implementation Method

This  study utilized  the developmental  type  of  research. An electrical Fault trainer comprised of A 36 inches by 42 inchs 18 guage metal body which served as  a trainer board placed on a metal frame having 2 legs with a length of  15  inches which  served as  a stand. It was equipped with a low current circuit breaker to facilitate safe operations and eliminate damages to all the devices.  It was  capable  of  handling  a  residential-like,  commercial-like and  industrial-like  electrical  wiring / installation, troubleshooting,  and  commissioning.

Benefits of the Project

This training set provides students with the opportunity to practice a method of error on the basic malfunctions in Electrical circuits. This set aims to inform students about the most common faults can generate 30 basic faults, such as;

?Fault in emergency Red Lamp.

?Push button ON-2 (NO).

?Push button ON-1 (NO).

?Time Delay Relay ( A2 Coil).

?Magnatic Contactor-1 (L1).

?Magnatic Contactor-1 ( Auxilary NO 13/14).

?Time Delay Relay (Comon).

?Emergency Push Button. (NC).

?Magnatic Contactor-3 (A1 Coil).

?Thermal Over Load (97).

?Thermal Over Load (95).

Technical Details of Final Deliverable

This training set provides students with the opportunity to practice a method of error on the basic malfunctions in Electrical circuits. This set aims to inform students about the most common faults can generate 30 basic faultsThe trainer has some main components as follows:

1.Main Miniature Circuit Breaker (MCB)   Three phase 32A.

2.Regulated Cam Switch 1,0,2..

3.Control Miniature Circuit Breaker (MCB)   Single Phase 6A.

4.Push Button for Emergency Stop.

5.Power Indicator Lamp for LI/R, L2/Y, L3/B

6.Magnetic Contactor Three Main Pole, Auxiliary Contact 2NO, 2NC Coil 220VAC.

7.Control Lamp Indicator for Run, Overload, Emergency.

8.Time Delay Relay (ON Delay Timer)

9.Thermal Overload Relay 1-1.6A

10.Push Button Switches NO/NC 12. Fault Simulator Switches

11.Set of Test Leads

12.Power Cable

13. Fault Simulator Switches

Final Deliverable of the Project Hardware SystemCore Industry EducationOther Industries Manufacturing Core Technology OthersOther TechnologiesSustainable Development Goals Quality EducationRequired Resources

Item Name	Type	No. of Units	Per Unit Cost (in Rs)	Total (in Rs)
			Total in (Rs)	73395
3-pole Miniature Circuit breaker	Equipment	1	5000	5000
1-pole miniature Circuit Breaker	Equipment	1	800	800
3-Phase Magnetic Contactor	Equipment	3	4800	14400
3-Phase selector Switch	Equipment	1	2500	2500
Emergency Switch	Equipment	1	1000	1000
Thermal overload relay	Equipment	1	3500	3500
Time Delay Relay	Equipment	1	2000	2000
Push Button	Equipment	1	400	400
Structure frame	Equipment	1	12000	12000
Front Vinyl Sheet	Equipment	1	4000	4000
Miscellanea Transport	Miscellaneous	3	300	900
cutting disk	Miscellaneous	5	150	750
drill bits	Miscellaneous	2	500	1000
hole saw	Miscellaneous	1	1000	1000
Indication Lamp	Equipment	6	100	600
Heavy Male/Female Connectors	Equipment	150	100	15000
3/0.029 Cable	Equipment	1	2800	2800
2 mm Flexible Cable	Equipment	1	3500	3500
Screw	Miscellaneous	2	200	400
Nuts & bolts	Miscellaneous	35	27	945
Nuts & bolts 1/2	Miscellaneous	30	30	900