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Training Unit
Electrical Installation 1
Theory
No: EE 020
Training Unit
Electrical Installation 1
Theoretical Part
No.: EE 020
Edition:
2008
All Rights Reserved
Editor:
CONTENTS
Page
Accident safety.....................................................................................................6
1.2
1.3
General layout......................................................................................................7
2.2
2.3
2.4
2.5
2.6
2.7
CIRCUIT DIAGRAMS.................................................................................................15
3.1
3.2
3.3
4.2
4.3
4.4
4.5
4.6
4.7
4.8
5.2
5.3
Rigid plastic conduit - yellow or light grey (Eurogrey to RAL 7035) ...................29
5.4
Flexible plastic conduit - yellow or light grey (Eurogrey to RAL 7035) ...............30
5.5
5.6
5.7
5.8
5.9
5.10
Galvanized flexible conduit with or without woven sheath (Peschel hose) ........32
5.11
5.12
5.13
5.14
5.15
6.1.1
NY-cables.......................................................................................................38
6.1.2
6.1.3
NYM cable......................................................................................................39
6.1.4
6.2
6.2.1
7
Laying ................................................................................................................27
Fuses .................................................................................................................42
Screw cap fuses.............................................................................................42
7.1.2
7.1.3
7.1.4
7.2
9.2
ELECTRICAL INSTALLATION 1
LEARNING OBJECTIVES
The trainee should ...
state the three guidelines for carrying out electrical installation work
describe the three types of circuit diagram which are required for electrical Installation
outline the permitted and prohibited methods of laying NY, NYM parallel twin cables
and NYM cables
state the rated currents and colour marking of cartridge fuses from 2A to 100A
state the regulations for connecting switches in installations and for connecting cables
to plugs
ELECTRICAL INSTALLATION 1
GENERAL REQUIREMENTS
Every electrical installation must comply with the general requirements of the electricity
supplier.
The following rules must be obeyed:
-
1.1
Accident safety
It must be impossible to touch "live" parts. If necessary, protective measures must be
taken against contact voltage.
The insulation resistance between wire and wire and between wore and earth must
not be less than:
1000 /V of operating voltage in dry and damp rooms
500 /V of operating voltage in wet rooms and out of doors
A socket should be provided for each piece of portable electrical equipment (this
prevents the use of adaptors and multi-plugs, which are contrary to regulations).
1.2
Operational reliability
Installations must be so constructed that they resist the effects of impacts and knocks,
dust, damp and humidity.
The cables must be protected by the specified fuses against overload and shortcircuit.
Electrical machinery with loads above 1.5 kW should be installed in individual spur
circuits.
1.3
General layout
The inside of a distribution board must be easily visible. The switches and fuses must
be labelled.
The wires of only one circuit may be run (laid) in a conduit or contained within the
sheath of a cable.
Exception:
Control and Signal wires for several circuits may be run in a common sheath but must
be separated from the main power circuits.
Several power circuits may be pulled through one junction box or distribution box
(branching box) if the cables are not terminated.
If there are branches or connections, the power circuits must be separated by insulating
partitions.
2.1
2.2
Generators
Transformers
2.3
10
11
2.4
Fuses, switches
Single pole fuse
Pushbutton
2.5
Socket
Multiple socket (e.g. triple socket)
12
Safety socket
Multiple safety socket
Switched socket
Safety socket for 3-phase alternating current
Safety plug
2.6
Other equipment
Ammeter
Voltmeter
Wattmeter
Counter
Alarm bell
Pulsed stepping switch
13
2.7
Telecommunications equipment
Socket for telecommunication circuits
(telephone and aerials etc.)
Telex
General telecommunications device
General telephone equipment,
domestic telephone equipment
14
CIRCUIT DIAGRAMS
3.1
3.2
15
3.3
The cable runs are indicated as a single line in the plan of the building, using conventional
symbols.
16
Single-pole switches
Intermediate switches
Pulsed relays
4.1
The most frequently used switch in lighting circuits is the single-pole switch.
17
4.2
Two-pole switches are specified by the electricity supply authority for connecting radiators
and water heating equipment etc. Three-pole switches are required for three-phase
equipment.
18
19
4.3
Single-pole two-way switches are provided for the selective switching of two incandescent
lamps or groups of incandescent lamps (they have now been replaced by multiple switch
units).
20
4.4
Units containing two single-pole one-way switches are used for switching two
incandescent lamps or groups of lamps either individually or together.
21
4.5
Changeover switches, single-pole two-way switches, are used for switching one or more
incandescent lamps on and off from two places.
22
23
4.6
Intermediate switches together with two changeover switches make it possible to switch
on and off from three or more places.
24
4.7
Impulse relay switching is used to switch one or more loads on and off independently from
one or more places. The impulse relay is an electro-magnetically actuated switch, which is
activated by pushing any of the pushbuttons Q1, Q2 and Q3.
When one of the switches is pressed the impulse relay is activated and the three loads
light up.
25
4.8
Staircase time switches are used for staircase illumination (in blocks of flats). The time
switch is started by pressing a pushbutton, and switches itself off after a set time of
several minutes.
By actuating a pushbutton switch, the armature coil pulls in and the current circuit is
closed. The current circuit remains closed until the switching contact is switched off after
the set delay period.
One can switch over to continuous illumination using the switch installed in the contactor
unit K1.
26
5.1
Laying
5.1.1
it is resistant to breakdowns.
it is resistant to corrosion.
Conduits must be laid in such a way that no water can collect in them.
For installations an plaster, the distance between clamps (saddles) given in the table
overleaf must not be exceeded.
Double strap clamps must be used for conduit size 21 upwards.
27
Type of conduit
Horizontal run
Vertical run
Plastic conduit
40 cm
70 cm
60 cm
80 cm
"Peschel" conduit
70 cm
100 cm
Steel conduit
100 cm
130 cm
Close attention should be paid to the permitted number of cables in the conduits.
28
5.2
5.3
Rigid plastic conduit - yellow or light grey (Euro grey to RAL 7035)
29
5.4
5.5
30
5.6
Nominal sizes:
11, 13.5, 16, 21, 29, 36, 48
Properties:
Pressure tight, non inflammable, temperature resistant from -20C to 70C, highly
insulating, safe for human contact
Application:
For laying on and under plaster, on wood and in concrete.
Accessories:
Couplings, bends, clamps and junction boxes
5.7
5.8
31
Application:
For laying in heavy concrete and for machine connections. It can be firmly screwed into
steel accessories.
Nominal sizes:
11, 13.5, 16, 21, 29, 36, 48
Accessories:
Couplings, bends, clamps and junction boxes
5.9
5.10 Galvanized flexible conduit with or without woven sheath (Peschel hose)
Nominal sizes and accessories:
As for overlapping steel armoured conduit
32
33
34
Nominal
Radius of
External
Internal
Cable
mm
mm
mm
mm
Cross-
Cross-
sectional
sectional
area of
area of
cable mm conduit mm
1"
350
32.0
28.0
up to 16
201
616
1 1/4"
400
40.0
35.2
up to 20
314
973
1 1/2"
500
50.0
44.0
up to 25
490
1520
2"
650
63.0
55.4
up to 32
804
2409
2 1/2"
750
75.0
66.0
up to 38
1134
3420
3"
900
90.0
79 4
up to 46
1662
4949
3 1/2"
1100
110.0
97 0
up to 56
2462
7386
4"
1250
125.0
110.0
up to 63
3116
9533
35
Fixing:
By gluing, riveting or screwing.
Advantages:
Wiring can be carried out quickly and there is protection from mechanical damage.
36
Width
mm
mm
mm
mm2
15
15
11
15
25
25
13
30
40
25
13
45
40
40
30
70
40
60
35
115
40
80
35
160
40
150
90
300
40
200
140
450
60
60
35
170
60
80
35
220
60
100
35
270
60
120
55
340
60
150
90
440
60
200
140
550
80
40
30
180
80
80
65
295
Advantages:
Electrical cables can be laid with a saving of space and cost, and in a fully insulated
enclosure in the shortest possible time.
37
LAYING CABLES
6.1
Permanent cabling
The following cables are mainly laid in buildings and out of doors.
6.1.1
CENELEC
HO7V-U
HO7V-R
A05VV-U
VE
Ye
Ym
YM Steg
YM
Austrian
VDE
NYAe
NYAm
NYIF
NYM
German
NY-cables
Permitted:
In dry rooms in buildings for laying in conduits.
Not permitted:
For laying in plaster and out of doors.
NY-cables must always be protected from mechanical damage by conduits or covers
Above 10 mm, NYAm cables are used, as solid core cables of large cross section are
very stiff.
6.1.2
Permitted:
In and under plaster on a fire-resistant base in dry rooms in buildings.
Not permitted:
In wooden rooms, even with fire-resistant base; in bathrooms and shower rooms; in
agricultural buildings; as metering cables, in sales rooms, stores and workshops of
warehouses and businesses.
If a parallel twin cable is used, it must be firmly fixed to the wall along its entire length by:
-
Plastering,
Gluing
38
It is not permitted to fix NYM parallel twin cables with nails or staples as the insulation of
the sheath can easily be damaged.
If two parallel twin cables are laid in parallel they should be spaced at least 2 cm apart.
The circuit and insulation resistance should be checked after any painting work has been
carried out.
6.1.3
NYM cable
Permitted:
In dry rooms in buildings and out of doors, in and under plaster.
Not permitted:
Laid in the ground.
39
6.1.4
6.2
Electrical equipment which moves during operation or which is portable (e.g. hand drills,
kitchen equipment, irons and electric cookers etc.) is called portable equipment. This type
of equipment must be connected through plugs and flexible cables.
Flexible cables are, therefore, especially exposed to mechanical loads and the correct
choice of cable must be made. They must be carefully mounted and maintained. The point
at which the cable enters the equipment and the plugs is a particular danger point.
Flexible cables may have either plastic insulation (Y) or rubber insulation (G). They obtain
their flexibility by having cores made of thin or very thin copper wires.
40
6.2.1
The rated current of the plug must be at least as great as the rated current of the piece
of equipment.
To ensure that cores do not break off at the point of connection, they should be
secured by cable clamps and cable end sleeves.
Protective earth conductors must be left longer than the other conductors, so that if the
cable clamp falls, they will break last of all.
Extension cables must never be fitted with male connectors (plugs) at both ends.
Extension cables must be matched to the rated current of the plugs to which they are
connected.
Do not use undersize leads.
Cables rolled on drums must not carry their full current due to poor cooling and
inductance effects.
41
CABLE PROTECTION
Each cable is heated when current flows through it. If the current is too great during a
short-circuit overload, then the excessive heat will destroy the cable insulation. Each cable
must, therefore, be protected against short-circuits and overload. An over-current
protective device carries out this function.
There are two types of device:
-
Fuses;
7.1
Fuses
A fuse is a deliberately inserted section of reduced cable cross section which melts when
there is a short-circuit, over-current or earth fault, and, therefore, protects the cables and
equipment from excessive heating.
7.1.1
Diazed fuses are manufactured for rated currents of 2 A to 200 A and a nominal voltage of
500 V
Neozed fuses are appreciably smaller than diazed fuses, but are constructed on the same
principle. They are manufactured for rated currents of 2 A to 100 A and with a nominal
voltage of 380 V.
42
The following code letters are used to identify fuse bases according to their type of
construction:
UZ
- universal bases
TZ
FZ
NDZ
- neozed bases
43
1. top contact
2. support wire
3. quartz sand
4. fuse wire
5. cap
6. spring
7. porcelain body
8. bottom contact
The rated current of the cartridges are standardized and are indicated by colours on the
caps In order to prevent fuse link from being wrongly used for currents which are too high,
the feet of the fuse link have different diameters, according to the current rating. The feet
of the fuse link fit the diameters of the base inserts. Therefore, fuse links with a high
current rating do not fit into base inserts suitable for low current ratings.
NOTE:
Fitting screws must not be replaced by others with higher rated fusing currents. Fuses
must not be mended or bridged.
44
Current ratings, colours for cartridges and fittings screws and sizes of screw cap fuses:
Diazed
Rated
current A
Thread
E 27
E 33
R 1 1/4"
R 2"
Size
D II
D III
D IV
DV
Neozed
Colour
pink
brown
green
10
red
16
grey
20
blue
25
yellow
35
black
50
white
63
copper
80
silver
100
red
125
yellow
160
copper
200
blue
45
Size
Thread
D 01
E 14
D 02
E 18
D 03
M 30.2
7.1.2
Power fuses have appreciably higher breaking currents (100 kA). The parts carrying
current (knife contacts) of the power fuse link are not covered. Therefore, they must not
be accessible to the layman, and must only be replaced by a technician. The insulated
fuse puller is used for this purpose. Power fuse links must only be pulled out or pushed in
with power removed.
Great care must be taken when inserting fuse links!
Fuse insulators are used in 3-phase networks, where the fuse links can be replaced off
lad. It is impossible to touch live parts.
Sizes of power fuses
Size
00
6 A to 100 A
10 A to 160 A
36 A to 250 A
36 A to 400 A
300 A to 630 A
46
7.1.3
These are mainly used in low power equipment (electronic equipment, electronic
equipment for entertainment), and are also used in the car industry. In contrast to other
fuses, there is no colour marking of fuse links. The data for these fuses (such as voltage,
current and breaking capacity) are given on the contact caps or on the body of the fuse.
1. metal caps
2. fuse wire
3. insulating tube
Design:
The cylindrical contact caps are insulating tube is made of glass or ceramic material.
Cap diameter:
5 2 mm.
Length:
20 mm.
Rated voltage:
250 V.
Rated current:
32 mA to 10 A.
7.1.4
According to time taken to melt the fuse, when excessive current flows, the fuses are
classified as:
-
Superfast
Fast
Medium fast
Slow
47
1. superfast
2. fast
3. medium fast
4. slow
48
Testing fuses
In order to test a fuse, the fuse cartridge is removed and is tested using an ohmmeter. For
a blown (open) fuse the ohmmeter reads infinity.
7.2
Instead of fuses, circuit breakers can be used. They are reset after tripping.
49
Construction
The magnetic trip provides short-circuit protection for the cable. The thermal trip (bimetal
strip) provides over current protection.
Design:
Overload circuit breakers are made with different numbers of poles.
50
Overload circuit breakers are divided according to the setting of the magnetic and thermal
trips as follows:
L type:
This is the most frequently used circuit breaker, it is suitable for all applications and
corresponds to the tripping characteristic of a fuse of equal current rating.
Magnetic trip 5 x In
Thermal trip
1.4 x In
In
= rated current
51
Motor protection circuit breakers are 3-pole overload circuit breakers where the trips are
adjustable.
Detailed wiring diagram of motor protection circuit breaker:
The thermal over current trip is set at the rated motor current. The electro-magnetic trip is
set either at 8 - 16 times the rated circuit breaker current or at 10 times the rated motor
current when connecting up (observe the connecting instructions). On short-circuits the
current may be so great that the short-circuit trip trips, but an arc is maintained between
the open switch contacts. Therefore, fuses are connected in series with the circuit
breaker. Motor protection circuit breakers are often produced without magnetic trips for
this reason.
52
Switches and plug-in devices must comply with the recognised rules of electrical
technology. All materials used must carry the appropriate safety sign, which means that
these materials have been tested in a recognised testing station regarding their
compliance with regulations and their safety.
9.1
Installation of switches
The neutral conductor may only be interrupted, together with the live conductor in a
linked two pole switch.
In order to switch circuits containing more than two fluorescent lamps, the switches
must be rated for at least 10 A.
In two wire circuits with fuse or overload circuit breaker rated up to 10 A or domestic
overload circuit breakers rated up to 16 A, and with rated voltages up to 250 V.
NOTE:
At locations with operating temperatures above 60C, heat-resistant switches marked T
must be used.
53
9.2
Sockets for mounting on or in plaster of 2 and 3 pole design as: Single sockets fused
for 6 A or 10 A or not fused.
Protected sockets for 10 A or 16 A with sprung protective contacts (2 pins and earth).
Sealed sockets that may be switched off for damp rooms (garage sockets).
Encapsulated plug-in assemblies (shrouded plug and socket) with earthing pin for
damp rooms, out of doors and in rough locations. CEE shrouded plugs and sockets.
This international standard plug and socket system is suitable for rated currents of 16 A,
32 A, 125 A and 200 A, with a rated voltage of 24 V - 750 V DC or AC and a frequency up
to 500 Hz.
CEE equipment has a colour marking according to the rated voltage.
24 V - violet
220 V - blue
42 V - white
380 V - red
110 V - yellow
500 V - black
The pin and socket of the protective earth contact have a larger diameter than the live
conductor contacts. This ensures that even if the shroud breaks (groove or projection), lt
is not possible to insert the plug pins into the incorrect sockets.
There is a "pilot contact" in the middle of the insert for 63 A and 125 A plugs, which
enables an electrical interlock to be made.
This contact closes after the other contacts.
CEE power plugs are:
-
Reliable for the future, as they are used in all European countries.
54
Safe to operate, as the thicker protective earth contacts guarantee that poles cannot
be confused or the plug used for the wrong system.
Accident proof as they are fully insulated made of high-quality plastic material
(Makrolon) largely insensitive to temperature or resistant to fracture.
Plugs must be constructed for a rated voltage of 250 V and a minimum current of 10
A.
Portable equipment may be switched on and off by means of the plugs and sockets, if
the following ratings are not exceeded:
For DC 250 V/10 A.
For AC 250 V/16 A.
For 3-phase AC 380 V/10 A.
Only shrouded plugs and sockets should be used for connecting large loads.
In rooms where protective measures are required, only protected sockets with earth
wires may be used, apart from sockets for low voltages.
Plugs and sockets for connecting extension cables (couplings) must be mounted so
that the plug-in (male) contacts are not live with the connection uncoupled e.g.,
extension cables with plugs at both ends).
Plugs and sockets must be constructed so that there is no strain on the terminals of
the flexible cable.
55
EE 020
Electrical Installation 1
Theoretical Test
56
EE 020
ELECTRICAL INSTALLATION 1
TEST 1
1. State three rules that must be obeyed in electrical installation.
2. State the conditions under which cables for more than one power circuit may be drawn
through the same junction or distribution box.
3. What is meant by
57
EE 020
ELECTRICAL INSTALLATION 1
TEST 2
1. What is the purpose of conduits?
2. Name the advantages of an insulated conduit compared to a metal conduit.
3. Name two types of conduits used where the mechanical loading is light.
4. What are the properties of armoured black-plastic conduit?
5. State the application of steel armoured conduit.
6. What is the relationship between the cross sectional area of the conduit and the
maximum cross sectional area of the cables if contains?
7. Where is the wiring duct used?
8. Is it permissible to lay NY cable in plaster or outdoors?
9. Is it permitted to use NYM cable in damp places?
10. Make a sketch showing the methods of laying cables and conduits.
58
EE 020
ELECTRICAL INSTALLATION 1
TEST 3
59
EE 020
ELECTRICAL INSTALLATION 1
TEST 1
(Solution)
60
6. The cable runs are indicated as a single line in the plan of the building, using
abbreviated symbols.
61
9. Intermediate switches together with two two-way switches make it possible to switch
on and off from three or more places.
62
EE 020
ELECTRICAL INSTALLATION 1
TEST 2
(Solution)
63
64
EE 020
ELECTRICAL INSTALLATION 1
TEST 3
(Solution)
1. Portable electrical equipment (e.g. hand drills, kitchen equipment, irons and electrical
cookers etc.).
2. Each cable is heated when current flows through it. If the current is too great during
short-circuit or overload, then the excessive heat will destroy the cable insulation.
Each cable must therefore, be protected against short-circuits and overload. An
overload circuit breaker carries out this function.
3. A fuse is a deliberately inserted section conductor of reduced cross section which
melts when there is short-circuit, over current or earth fault, and, therefore, protects
the cables and equipment from excessive heating.
4. Diazed fuses are manufactured for rated currents of 2 A to 200 A and a nominal
voltage of 500 V.
Neozed fuses are manufactured for rated currents of 2 A to 100 A and with a nominal
voltage of 380 V.
65
1. top contact
2. support wire
3. quartz sand
4. fuse wire
5. cap
6. spring
7. porcelain body
8. bottom contact
6. These are mainly used in light current equipment (electronic equipment, electronic
equipment for entertainment), and are also used in the car industry.
7.
8. In order to test a fuse, the fuse cartridge is removed and tested using an ohmmeter,
for a blown fuse the ohmmeter reads infinity.
66
9. This is the most frequently used circuit breaker, which is suitable for all applications
and corresponds to the tripping characteristic of a fuse of equal current rating.
Magnetic trip 5 x In
Thermal trip 1.4 x In
In = rated current
10. With thermal trips
67
KEY TO EVALUATION
PER CENT
MARK
88 100
75 87
62 74
50 61
0 49
68