HCLT Confidential

ELECTRICAL COMPONENTS

Ganesh Kumar.M

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Agenda

VIISTA

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FUSE

A safety device that protects an electric circuit from becoming overloaded.

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FUSE

� Fuse - is a type of over current protection device.

� Its essential component is a metal wire or strip that

melts when too much current flows, which interrupts the

circuit in which it is connected.

� Short circuit, overload or device failure is often the

reason for excessive current

� A fuse interrupts excessive current (blows) so that

further damage by overheating or fire is prevented.

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MINIATURE CIRCUIT BREAKER (MCB)

An automatic switch that stops the flow of electric current in a suddenly overloaded or otherwise abnormally stressed electric circuit

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� when excessive current develops, a circuit breaker opens to protect

equipment .

� These abnormal currents are usually the result of short circuits

created by lightning, accidents, deterioration of equipment.

� A protective device that opens a circuit upon sensing a current

overload. Unlike a fuse, it can be reset.

MINIATURE CIRCUIT BREAKER (MCB)

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MCB WORKING

� Able to protect the wiring and the loads of electrical circuits.

� MCB’s are a Thermal-Magnetic type circuit breaker.

� Thermal part loads (motors, heaters, power supplies, etc.)

� will be protected from short circuits by its magnetic parts.

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MCB APPLN

� These are manufactured for fault level of up to 10KA.

� Only with operating current range of 0.5 to 63 Amps.

� Available types are single, double and three pole version.

� Mainly used for control voltage protection.

� Machine Lighting.

� Cooling unit.

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Type B devices are generally suitable for domestic applications. They may also

be used in light commercial applications where switching surges are low or

non-existent.

Type C devices are the normal choice for commercial and industrial

applications where fluorescent lighting, motors etc. are in use.

Type D devices have more limited applications, normally in industrial use

where high inrush currents may be expected. Examples include large battery

charging systems, winding motors, transformers, X-ray machines and some

types of discharge lighting.

Type B devices are designed to trip at fault currents of 3-5 times rated current

(In). For example a 10A device will trip at 30-50A.

Type C devices are designed to trip at 5-10 times In (50-100A for a 10A

device).

Type D devices are designed to trip at 10-20 times In (100-200A for a 10A

device).

MCB TRIPPING

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Curve Graph

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MOULDED CASE CIRCUIT BREAKER (MCCB)

An automatic switch that stops the flow of electric current in a suddenly overloaded or otherwise abnormally stressed electric circuit for high SC production.

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MCCB (Mould case circuit breakers)

� MCCB’s are Moulded case Circuit breakers, with

protection facilities of over current, earth fault.

� They are manufactured for fault levels of 16KA

to 50KA and operating current range of 25A to

630Amps.

� They are used for application related with larger

power flow requirement.

� In machines it is used for main supply

connection.

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MOTOR PROTECTION CIRCUIT BREAKER (MPCB)

An automatic switch that stops the flow of electric current in a suddenly overloaded or Short circuit protection.

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MPCB (MOTOR PROTECTION CIRCUIT BREAKER)

Motor Protection Circuit Breakers may

provide the following protective and

control functions.

� Disconnect for Motor Branch Circuit

� Branch-Circuit, Short-Circuit Protection

(Magnetic Protection)

� Overload Protection (Thermal Protection)

� High Current Limiting

� High Switching Capacity

� Current Range 0.1…630 A

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A relay is an electrically operated switch.

Relay

TYPES OF RELAY:

• Latching relay.

• Solid state relay.

• Over load protection relay.

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� Electrical device such that current flowing through it in one circuit can switch

on and off a current in a second circuit.

� Many relays use an electromagnet to operate a switching mechanism

mechanically.

� A relay is used to isolate one electrical circuit from another.

� It allows a low current control circuit to make or break an electrically

isolated high current circuit path.

� Normally-open (NO) contacts connect the circuit when the relay is

activated; the circuit is disconnected when the relay is inactive.

� Normally-closed (NC) contacts disconnect the circuit when the relay is

activated; the circuit is connected when the relay is inactive

Relay Operation

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CONTACTOR

A contactor is an electrically controlled switch used for switching a power circuit, similar to a relay except with higher current ratings.

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CONTACTOR

� A contactor is controlled by a circuit which has a much lower power level than the

switched circuit

� Unlike a circuit breaker, a contactor is not intended to interrupt a short circuit

current.

� A type of relay that can handle the high power required to directly control an electric

motor is called a contactor.

� Contactors typically have multiple contacts, and those contacts are usually

normally-open, so that power to the load is shut off when the coil is de-energized.

� The most common industrial use for contactors is the control of electric motors.

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PUSH BUTTONS

Actuating any function in the

machine can be done by Push Buttons.

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� It is a simple switch mechanism for controlling some aspect of a

machine or a process.

� Buttons are typically made out of hard material, usually plastic or

metal

� Pushbuttons are often color-coded to associate them with their

function so that the operator will not push the wrong button in error.

� Commonly used colors are RED for stopping the machine or

process and GREEN for starting the machine or process.

� Secured operations can be done by Key Switch.

PUSH BUTTON

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EMO Switch

Emergency Machine Off.

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EMO Switch

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CONNECTORS & CRIMPS

Connector is an Electro-Mechanical device for joining Electrical Circuits as an interface using a mechanical assembly.

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� A D-sub contains two or more parallel rows of pins or sockets

usually surrounded by a D-shaped metal shield that provides

mechanical support .

� The part containing pin contacts is called the male connector or

plug, while that containing socket contacts is called the female

connector or socket .

D-Sub CONNECTORS

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� Communications Ports (RS-232 serial communications )

� Network Ports. (Ethernet, network interface cards, )

� Computer Video Port. (VGA Adapters)

� Game Controller Port.

D-Sub CONNECTORS Appln

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� Circular Plastic Connectors (CPC).

� Lightweight, all-plastic connectors and metal-shell versions

available.

� CPC connectors are UL 94V-0 rated stabilized, heat resistant, self-

extinguishing thermoplastic material .

� Operating temperature range: -55°C - 105°C

� Unique contact pattern for each position size helps prevent

accidental mating with other position sizes

CPC CONNECTORS

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CABLES

A device for connecting electrical devices together.

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CABLES

Cable Basics

� Conductor is a material which contains movable electric charges.

� Of the metals commonly used for conductors, copper has a high conductivity. Silver

is more conductive, but due to cost it is not practical in most cases. Aluminum has

been used as a conductor in housing applications for cost reasons.

� Electrical Wires are either solid or stranded Conductors. "Solid Conductors" are

exactly that, one solid Wire. "Stranded Conductors" consist of a Wire made of a

number of smaller Wire strands wrapped around each other.

� The choice between solid or stranded depends on the need for flexibility in handling

and working with the Wire. Smaller electrical Wire Sizes are generally made of solid

Conductors; while Wires larger than Number 6 AWG are generally stranded.

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CABLES

� Insulation separates conductors electrically and physically within a cable.

� The jacket physically protects the internal components of a cable, improves the

cable’s appearance and provides flame redundancy.

� Protects from the environment

� Drain Wire Metallic conductor frequently used in contact with foil-type signal-cable

shielding to provide a low-resistance ground return at any point along the shield.

� Twisted pair cabling is a type of wiring in which two conductors (the forward and

return conductors of a single circuit) are twisted together for the purposes of

canceling out electromagnetic interference (EMI) from external sources; for instance,

electromagnetic radiation from unshielded twisted pair (UTP) cables, and crosstalk

between neighboring pairs.

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AMERICAN WIRE GAUGE(AWG)

American wire gauge (AWG) is a standardized wire gauge system

used predominantly in the United States and Canada for the

diameters of round, solid, nonferrous, electrically conducting wire.

The cross-sectional area of each gauge is an important factor for

determining its current-carrying capacity

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AWG TABLE

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SHRINK TUBING

Shrink tubing - is a sleeve ordinarily made of nylon or polyolefin, which shrinks in diameter when heated.

HCLT ConfidentialSlide 33

� Its diameter and thickness can vary. Heat shrink tubing is rated by its

expansion ratio, a comparative of the differences in expansion and recovery

rate.

� Heat shrink is used to insulate wires offering abrasion resistance and

environmental protection for stranded and solid wire conductors,

connections, joints and terminals in electrical engineering.

� To protect wires or small parts from minor abrasion, and to create cable

entry seals.

� Common shrink ratio is 2:1, while high-grade polyolefin heat shrink is

available in 3:1

� Heat shrink tubing is available in a variety of colors to allow easier color

coding of wires and connections

Heat Shrink Tubing

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Heat Shrink Tubing

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SHIELDING

Shielding - Contains electrical energy so that the signal on the cable does not radiate and interfere with signals in other nearby cables and circuitry.

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� It is the process of reducing the electromagnetic field in a space by

blocking the field with barriers made of conductive and/or magnetic

materials .

� Shielding is typically applied

� 1) to enclosures to isolate electrical devices from the 'outside world' and

� 2) to cables to isolate wires from the environment through which the

cable runs

� The cable shielding and its termination must provide a low-

impedance path to ground. .

� A shielded cable that is not grounded does not work effectively.

� Make sure the equipment that the cable is connected is properly

grounded.

SHIELDING

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SHIELDING

•Protects the signal from external interference.

Shielding materials-

� Metallic foil

� Braid

� French braid™

� Spiral (serve)

� Semi-conductive

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GROUNDING

Ground or Earth may be the reference point in an electrical circuit from which other voltages are measured

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� In mains powered equipment, exposed metal parts are connected to

ground to prevent contact with a dangerous voltage if electrical

insulation fails.

� An electrical ground system should have an appropriate current-

carrying capability in order to serve as an adequate zero-voltage

reference level.

� Signal Ground is a reference point from which that

signal is measured.

� Chassis ground is the box or frame in which

a circuit is built.

GROUNDING

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TERMINALS

A device for joining electrical circuits together

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� A terminal is the point at which a conductor from an electrical

component, device or network comes to an end and provides a point

of connection to external circuits .

� A screw terminal is a type of electrical connector where a wire is

clamped down to metal by a screw .

TERMINALS

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BusBar

A device used for Making Multi- Connection

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� In electrical power distribution, a busbar is a thick strip of copper or

aluminum that conducts electricity within a switchboard, distribution board,

substation or other electrical apparatus.

� Busbars are used to carry very large currents, or to distribute current to

multiple devices within switchgear or equipment.

� Busbars are typically either flat strips or hollow tubes as these shapes allow

heat to dissipate more efficiently due to their high surface area to cross-

sectional area ratio.

BusBar

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PD overview

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