TODAY’S LEARNINGS.

1. Basic details of electrical power circuit.

2. Components of power ckt.& its function.
3.How contactors works and its usage in electrical circuits.
4. Control ckt and its need.
5. Basic control ckts. and how it works
6. Control and power ckt demonstration
7. How to read a electrical ckt drawing.
a. Power ckt.
b. Control ckt.
8. How to approach to diagnose a fault.
9. Points to remember during replacement of a components from ckt.
10. Common electrical fault in RMHP.
 POWER CIRCUIT

What is electrical power ckt?

A power circuit is defined as ”any circuit which is

used to carry electricity that operates a load”.
 Different Types of Power ckt.
3 line Diagram

Motor Power ckt Welding power ckt UPS power ckt

AC power ckt
Different Types of Power ckt
Single line diagram
Conveyor Power ckt.
• Reversible Shuttle conveyor feeder.
 Component of Power ckt
• What are the main component of Power ckt?
• Circuit breaker- MCCB/MCB/VCP
• Circuit controller – Power Contactor MCCB

• Load protector- Relays

CONTACTOR (C)

OLR

Motor
 Component of Power ckt.
• What is the purpose of these components.?
• Circuit breakers are used for..
1. breaking the ckt. to stop the flow of power
further.
2. Provide protection to the load from different
types of faults like Earth fault, Short
circuit fault, Overload instantaneous etc.
3. It also provide isolation of one part of ckt from
other parts.
 Component of Power ckt.
• Power Contactor:
“A contactor is a special type of switch used for
switching an electrical circuit on or off.”
1. This is the major component to control the
flow of power.
2. This breaks the circuit but it can be
controlled electrically.
“ A control ckt is required to control contactor
electrically.”
 Component of Power ckt.
• Relays :
 This is for the protection of driven load from overload, ground , short ckt etc.
 It breaks the power ckt itself and gives signal to control ckt hence protect the
load.

Different types of relays installed in RMHP

1. bi-metallic type OLR
In this type of relays only one or two signal can be taken in interlocks
2. Intelligent relays
In this types relays communication can be done with PLC and other interlocks
also interlinked with the relays
a. BMP side P&B make.
b. 825P relays Rockwell make.
 Components of Power ckt.
• Working principle of Bimetallic OLR.
 Component of Power ckt.
What is a contactor and how it works??
• “A contactor is an electrically-controlled switch used for
switching an electrical power circuit.”
• Depending on the usage and its contacts rating it can be
used as power contactor or auxiliary contactor.
• In contactor there is a coil and mechanically latched
contacts.
• Contacts can be Normally open (NO) or Normally closed
(NC).
• Why it is normally open or normally close contacts. Why
not simply open or close contacts??.
• Power contactors
• Internal mechanism of a contactor?
 3. Control ckt and its need.
What will happen if there will be only MCCB??

MCCB

Motor
 3. Control ckt and its need.
Why contactor is used in the circuit??

MCCB

CONTACTOR

Motor
Why contactor is used in the circuit??

Phase (P)

230 V single
MCCB
phase control
supply
CONTACTOR (C)

A1

Coil of Contactor C

Motor Neutral N A2
 Why contactor is used in the circuit??
• Imagine a circuit like this?
Phase (P)

230 V single
MCCB
phase control
CONTACTOR (C) supply

A1

Coil of Contactor C

Motor Neutral N A2
 Why contactor is used in the circuit??
Imagine a circuit like this?
Phase (P)

230 V single
MCCB
phase control
CONTACTOR (C) supply

A1

Coil of Contactor C

Motor Neutral N A2
Why contactor is used in the circuit??
Phase (P)

230 V single
MCCB
phase control
supply
CONTACTOR (C)
ON Push
Button

A1

Motor Neutral N Coil of Contactor C

A2
Why contactor is used in the circuit??
Phase (P)

230 V single
MCCB
phase control
supply
CONTACTOR (C)
ON Push
Button

A1

Motor Neutral N Coil of Contactor C

A2
Why contactor is used in the circuit??
Phase (P)

230 V single
MCCB
phase control
supply
CONTACTOR (C)
ON Push
Button

A1

Motor Neutral N Coil of Contactor C

A2
Why contactor is used in the circuit??
Phase (P)

230 V single OFF Push

MCCB Button
phase control
supply
CONTACTOR (C)
ON Push
Button

A1

Motor Neutral N Coil of Contactor C

A2
Why contactor is used in the circuit??
Phase (P)

230 V single OFF Push

MCCB Button
phase control
supply
CONTACTOR (C)
ON Push
Button

A1

Motor Neutral N Coil of Contactor C

A2
What is Holding contact???
Why contactor is used in the circuit??
Phase (P)

230 V single OFF Push

MCCB Button
phase control
supply
CONTACTOR (C)
Holding contact ON Push
C Button

A1

Coil of Contactor C

Motor Neutral N A2
Why contactor is used in the circuit??
Phase (P)

230 V single OFF Push

MCCB Button
phase control
supply
CONTACTOR (C)
Holding contact ON Push
Button
C

A1

Coil of Contactor C

Motor Neutral N A2
Why contactor is used in the circuit??
Phase (P)

230 V single OFF Push

MCCB Button
phase control
supply
CONTACTOR (C)
ON Push
Holding contact C Button

A1

Coil of Contactor C

Motor Neutral N A2
Why contactor is used in the circuit??
Phase (P)

230 V single OFF Push

MCCB Button
phase control
supply
CONTACTOR (C)
ON Push
Holding contact C Button

A1

Coil of Contactor C

Motor Neutral N A2
Why contactor is used in the circuit??
Phase (P)

Emergency stop

230 V single OFF Push

MCCB Button
phase control
supply
ON Push
CONTACTOR (C)
Holding contact C Button

A1

Coil of Contactor C

Motor Neutral N A2
Why contactor is used in the circuit??
Phase (P)

Emergency stop

230 V single OFF Push

MCCB Button
phase control
supply
ON Push
CONTACTOR (C)
Holding contact C Button

OLR
OLR
A1

Coil of Contactor C

Motor Neutral N A2
Why contactor is used in the circuit??
Phase (P)

Emergency stop

230 V single OFF Push

MCCB Button
phase control
supply
ON Push
CONTACTOR (C)
Holding contact C Button

OLR
OLR
A1

Coil of Contactor C

Motor Neutral N A2
Why contactor is used in the circuit??
Phase (P)

Emergency stop

230 V single OFF Push

MCCB Button
phase control
supply
ON Push
CONTACTOR (C)
Holding contact C Button

OLR
OLR
A1

Coil of Contactor C

Motor Neutral N A2
Why contactor is used in the circuit??
Phase (P)

E stop

OFF PB
MCCB PCS BSS
230 V single c1
phase control c2
supply
C
ON PB
C
OLR

OLR
A1
C c1 c1

Motor A2
Neutral N
Why contactor is used in the circuit??
Phase (P)

E stop

OFF PB
MCCB PCS BSS
230 V single c1
phase control c2
supply
C
ON PB
C
OLR

OLR
A1
C c1 c1

Motor A2
Neutral N
Why contactor is used in the circuit??
Phase (P)

E stop

OFF PB
MCCB PCS BSS
230 V single c1
phase control c2
supply
C
ON PB
C
OLR

OLR
A1
C c1 c1

Motor A2
Neutral N
Why contactor is used in the circuit??
Phase (P)

E stop

OFF PB
MCCB PCS BSS
230 V single c1
phase control c2
supply
C
ON PB
C
OLR

OLR
A1
C c1 c1

Motor A2
Neutral N
Why contactor is used in the circuit??
Phase (P)

E stop
OFF PB
MCCB c1 PCS BSS
230 V single
phase control c2
supply` M
C
R
ON PB
C
OLR

OLR
R M
A1
C c1 c1

Motor A2
Neutral N
Why contactor is used in the circuit??
Phase (P)

E stop
OFF PB
MCCB c1 PCS BSS
230 V single
phase control c2
supply` M
C
R
ON PB
C
OLR

OLR
R M
A1
C c1 c1

Motor A2
Neutral N
Why contactor is used in the circuit??
Phase (P)

E stop
OFF PB
MCCB c1 PCS BSS
230 V single
phase control c2
supply` M
C
R
ON PB
C
OLR

OLR
R M
A1
C c1 c1

Motor A2
Neutral N
6. How to read electrical circuit
 How to approach to diagnose a fault
1. To diagnose a fault we must know the sequence of operation of the
equipment e.g. Conveyor operation, WT & SAC , Yard Machine Crusher,
Rod Mill etc.
2. Physical inspection of the particular feeder and equipment must be done
in first hand.
3. Look for the interlocks of equipment with another equipment e.g.
Conveyor interlocks??, WT with SAC interlocks, BWF interlocks with load
etc.
4. If interlock is healthy then try to isolate the equipment which is having
fault.
5. To isolate the equipment take it in local mode and try to start If started
then it is interlock issue.
6. If not started then diagnose through control ckt by checking the control
voltage at each terminal throughout the control ckt up to contactor coil ,
and find out the break in passing voltage or check continuity of ckt.
Points to remember during replacement of a
components from ckt.
1. Replacement of switch gear by matching
following details.
a. Model no.
b. Must check rating.
c. Coil voltage must be same.
d. Frame size /Fitting
e. Must use proper tools
f. Stock updating in store.
Common Electrical faults in RMHP.
1. Tripping of control supply.
2. Tripping of main power MCCB.
3. Tripping OLR
4. Flash over at feeder.
5. Equipment not starting.
6. CBS operated/ ZSS, BSS PCS operated L/s
operated.
7. Crusher/Rod mill Bearing temp high.
Thank you