ELECTRICAL COMPONENTS

Ganesh Kumar.M

AgendaAgenda

FUSEFUSE

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

FUSEFUSE

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

Its essential component is a metal wire or strip that Its essential component is a metal wire or strip that

melts when too much current flows, which melts when too much current flows, which

interrupts the circuit in which it is connected.interrupts the circuit in which it is connected.

Short circuit, overload or device failure is often the Short circuit, overload or device failure is often the

reason for excessive currentreason for excessive current

A fuse interrupts excessive current (blows) so that A fuse interrupts excessive current (blows) so that

further damage by overheating or fire is prevented.further damage by overheating or fire is prevented.

MINIATURE CIRCUIT BREAKER MINIATURE CIRCUIT BREAKER (MCB)(MCB)

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

when excessive current develops, a circuit breaker opens to when excessive current develops, a circuit breaker opens to protect equipment .protect equipment .

These abnormal currents are usually the result of short These abnormal currents are usually the result of short circuits created by lightning, accidents, circuits created by lightning, accidents, deteriorationdeterioration of of equipment.equipment.

A protective device that opens a circuit upon sensing a A protective device that opens a circuit upon sensing a current overload. Unlike a fuse, it can be reset.current overload. Unlike a fuse, it can be reset.

MINIATURE CIRCUIT BREAKER (MCB)MINIATURE CIRCUIT BREAKER (MCB)

MCB WORKINGMCB WORKING

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

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

ThermalThermal part loads (motors, heaters, power supplies, etc.) part loads (motors, heaters, power supplies, etc.)

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

MCB APPLNMCB APPLN

These are manufactured for fault level of up to 10KA.These are manufactured for fault level of up to 10KA. Only with operating current range of Only with operating current range of 0.5 to 63 Amps0.5 to 63 Amps.. Available types are single, double and three pole version. Available types are single, double and three pole version. Mainly used for control voltage protection.Mainly used for control voltage protection. Machine Lighting.Machine Lighting. Cooling unit.Cooling unit.

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 TRIPPINGMCB TRIPPING

Curve GraphCurve Graph

MOULDED CASE CIRCUIT BREAKER MOULDED CASE CIRCUIT BREAKER (MCCB)(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.

MCCB (Mould case circuit MCCB (Mould case circuit breakers) breakers)

MCCB’s are Moulded case Circuit MCCB’s are Moulded case Circuit

breakers, with protection facilities of breakers, with protection facilities of

over current, earth fault.over current, earth fault.

They are manufactured for fault levels They are manufactured for fault levels

of of 16KA to 50KA16KA to 50KA and operating and operating

current range of current range of 25A to 630Amps25A to 630Amps..

They are used for application related They are used for application related

with larger power flow requirement. with larger power flow requirement.

In machines it is used for main supply In machines it is used for main supply

connection.connection.

MOTOR PROTECTION CIRCUIT MOTOR PROTECTION CIRCUIT BREAKER (MPCB)BREAKER (MPCB)

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

MPCB (MOTOR PROTECTION CIRCUIT MPCB (MOTOR PROTECTION CIRCUIT BREAKER)BREAKER)

Motor Protection Circuit Breakers may Motor Protection Circuit Breakers may

provide the following protective and provide the following protective and

control functions. control functions.

Disconnect for Motor Branch Circuit Disconnect for Motor Branch Circuit

Branch-Circuit, Short-Circuit Branch-Circuit, Short-Circuit

Protection (Magnetic Protection) Protection (Magnetic Protection)

Overload Protection (Thermal Overload Protection (Thermal

Protection) Protection)

High Current Limiting High Current Limiting

High Switching Capacity High Switching Capacity

Current Range 0.1…630 ACurrent Range 0.1…630 A

Slide 15

A A relayrelay is an electrically operated switch. is an electrically operated switch.

Relay

TYPES OF RELAY:

• Latching relay.

• Solid state relay.

• Over load protection

relay.

Slide 16

Electrical device such that current flowing through it in one circuit Electrical device such that current flowing through it in one circuit can switch on and off a current in a second circuit.can switch on and off a current in a second circuit.

Many relays use an electromagnet to operate a switching Many relays use an electromagnet to operate a switching mechanism mechanically.mechanism mechanically.

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

It allows a low current control circuit to make or break an It allows a low current control circuit to make or break an electrically isolated high current circuit path.electrically isolated high current circuit path.

Normally-open (NO) Normally-open (NO) contacts connect the circuit when the relay contacts connect the circuit when the relay is activated; the circuit is disconnected when the relay is inactive.is activated; the circuit is disconnected when the relay is inactive.

Normally-closed (NC) Normally-closed (NC) contacts disconnect the circuit when the contacts disconnect the circuit when the relay is activated; the circuit is connected when the relay is relay is activated; the circuit is connected when the relay is inactiveinactive

Relay Operation

CONTACTORCONTACTOR

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

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

switched circuitswitched circuit

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

current.current.

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

electric motor is called a contactor.electric motor is called a contactor.

Contactors typically have multiple contacts, and those contacts are usually 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-normally-open, so that power to the load is shut off when the coil is de-

energized.energized.

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

PUSH BUTTONSPUSH BUTTONS

Actuating any function in the

machine can be done by Push Buttons.

It is a simple switch mechanism for controlling some aspect It is a simple switch mechanism for controlling some aspect of a of a machinemachine or a or a processprocess..

Buttons are typically made out of hard material, usually Buttons are typically made out of hard material, usually plasticplastic or or metalmetal

Pushbuttons are often Pushbuttons are often color-codedcolor-coded to associate them with to associate them with their function so that the operator will not push the wrong their function so that the operator will not push the wrong button in button in errorerror..

Commonly used colors are RED for stopping the machine Commonly used colors are RED for stopping the machine or process and GREEN for starting the machine or process.or process and GREEN for starting the machine or process.

Secured operations can be done by Key Switch.Secured operations can be done by Key Switch.

PUSH BUTTONPUSH BUTTON

EMO SwitchEMO Switch

Emergency Machine Off.

EMO SwitchEMO Switch

CONNECTORS & CRIMPSCONNECTORS & CRIMPS

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

A D-sub contains two or more parallel rows of pins or A D-sub contains two or more parallel rows of pins or sockets usually surrounded by a D-shaped metal shield that sockets usually surrounded by a D-shaped metal shield that provides mechanical support .provides mechanical support .

The part containing pin contacts is called the The part containing pin contacts is called the male male connectorconnector or or plugplug, while that containing socket contacts is , while that containing socket contacts is called the called the female connectorfemale connector or or socketsocket . .

D-Sub CONNECTORSD-Sub CONNECTORS

Communications Ports (Communications Ports (RS-232RS-232 serial communications ) serial communications ) Network Ports. (Network Ports. (EthernetEthernet, , network interface cardsnetwork interface cards, ), ) Computer Video Port. (VGA Adapters)Computer Video Port. (VGA Adapters) Game Controller Port.Game Controller Port.

D-Sub CONNECTORS ApplnD-Sub CONNECTORS Appln

Click

Circular Plastic Connectors (CPC). Circular Plastic Connectors (CPC). Lightweight, all-plastic connectors and metal-shell versions Lightweight, all-plastic connectors and metal-shell versions

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

extinguishing thermoplastic material .extinguishing thermoplastic material . Operating temperature range: -55° C - 105° C Operating temperature range: -55° C - 105° C Unique contact pattern for each position size helps prevent Unique contact pattern for each position size helps prevent

accidental mating with other position sizes accidental mating with other position sizes

CPC CONNECTORSCPC CONNECTORS

CABLESCABLES

A device for connecting electrical devices together.

CABLESCABLESCable Basics Cable Basics Conductor is a material which contains movable electric Conductor is a material which contains movable electric

charges.charges. Of the metals commonly used for conductors, copper has a Of the metals commonly used for conductors, copper has a

high conductivity. Silver is more conductive, but due to cost it high conductivity. Silver is more conductive, but due to cost it is not practical in most cases. Aluminum has been used as a is not practical in most cases. Aluminum has been used as a conductor in housing applications for cost reasons.conductor in housing applications for cost reasons.

Electrical Wires are either solid or stranded Conductors. "Solid Electrical Wires are either solid or stranded Conductors. "Solid Conductors" are exactly that, one solid Wire. "Stranded Conductors" are exactly that, one solid Wire. "Stranded Conductors" consist of a Wire made of a number of smaller Conductors" consist of a Wire made of a number of smaller Wire strands wrapped around each other.Wire strands wrapped around each other.

The choice between solid or stranded depends on the need for The choice between solid or stranded depends on the need for flexibility in handling and working with the Wire. Smaller flexibility in handling and working with the Wire. Smaller electrical Wire Sizes are generally made of solid Conductors; electrical Wire Sizes are generally made of solid Conductors; while Wires larger than Number 6 AWG are generally stranded.while Wires larger than Number 6 AWG are generally stranded.

CABLESCABLES InsulationInsulation separates conductors electrically and physically within a separates conductors electrically and physically within a

cable.cable. The jacket The jacket physically protects the internal components of a cable, physically protects the internal components of a cable,

improves the cable’s appearance and provides flame redundancy.improves the cable’s appearance and provides flame redundancy. Protects from the environment Protects from the environment

Drain Wire Drain Wire Metallic conductor frequently used in contact with foil-Metallic conductor frequently used in contact with foil-type signal-cable shielding to provide a low-resistance ground return type signal-cable shielding to provide a low-resistance ground return at any point along the shield. at any point along the shield.

Twisted pair Twisted pair cabling is a type of wiring in which two conductors (the cabling is a type of wiring in which two conductors (the forward and return conductors of a single circuit) are twisted forward and return conductors of a single circuit) are twisted together for the purposes of canceling out electromagnetic together for the purposes of canceling out electromagnetic interference (EMI) from external sources; for instance, interference (EMI) from external sources; for instance, electromagnetic radiation from unshielded twisted pair (UTP) cables, electromagnetic radiation from unshielded twisted pair (UTP) cables, and crosstalk between neighboring pairs.and crosstalk between neighboring pairs.

..

AMERICAN WIRE AMERICAN WIRE GAUGE(AWG)GAUGE(AWG)

American wire gauge (AWG) American wire gauge (AWG) is a standardized wire gauge is a standardized wire gauge system used predominantly in the United States and system used predominantly in the United States and Canada for the diameters of round, solid, nonferrous, Canada for the diameters of round, solid, nonferrous, electrically conducting wire. The cross-sectional area of electrically conducting wire. The cross-sectional area of each gauge is an important factor for determining its each gauge is an important factor for determining its current-carrying capacitycurrent-carrying capacity

AWG TABLE

SHRINK TUBINGSHRINK TUBING

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

Slide 33

Its diameter and thickness can vary. Heat shrink tubing is Its diameter and thickness can vary. Heat shrink tubing is rated by its expansion ratio, a comparative of the rated by its expansion ratio, a comparative of the differences in expansion and recovery ratedifferences in expansion and recovery rate..

Heat shrink is used to insulate wires offering abrasion Heat shrink is used to insulate wires offering abrasion resistance and environmental protection for stranded and resistance and environmental protection for stranded and solid wire conductors, connections, joints and terminals in solid wire conductors, connections, joints and terminals in electrical engineeringelectrical engineering..

To protect wires or small parts from minor abrasion, and to To protect wires or small parts from minor abrasion, and to create cable entry sealscreate cable entry seals..

Common shrink ratio is 2:1, while high-grade polyolefin Common shrink ratio is 2:1, while high-grade polyolefin heat shrink is available in 3:1heat shrink is available in 3:1

Heat shrink tubing is available in a variety of colors to allow Heat shrink tubing is available in a variety of colors to allow easier color coding of wires and connectionseasier color coding of wires and connections

Heat Shrink Tubing

Heat Shrink Tubing

SHIELDINGSHIELDING

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

It is the process of reducing the It is the process of reducing the electromagnetic fieldelectromagnetic field in a in a space by blocking the field with barriers made of space by blocking the field with barriers made of conductiveconductive and/or magnetic materials and/or magnetic materials ..

Shielding is typically appliedShielding is typically applied 1) to enclosures to isolate electrical devices from the 1) to enclosures to isolate electrical devices from the

'outside world' and 'outside world' and 2) to cables to isolate wires from the environment through 2) to cables to isolate wires from the environment through

which the cable runs which the cable runs The cable shielding and its termination must provide a low-The cable shielding and its termination must provide a low-

impedance path to ground. .impedance path to ground. . A shielded cable that is not grounded does not work A shielded cable that is not grounded does not work

effectively.effectively. Make sure the equipment that the cable is connected is Make sure the equipment that the cable is connected is

properly grounded.properly grounded.

SHIELDINGSHIELDING

SHIELDINGSHIELDING

••Protects the signal from external interference.Protects the signal from external interference.

Shielding materials- Shielding materials- Metallic foilMetallic foil BraidBraid French braid™French braid™ Spiral (serve)Spiral (serve) Semi-conductiveSemi-conductive

GROUNDINGGROUNDING

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

In In mainsmains powered equipment, exposed metal parts are powered equipment, exposed metal parts are connected to ground to prevent contact with a dangerous connected to ground to prevent contact with a dangerous voltage if voltage if electrical insulationelectrical insulation fails fails..

An electrical ground system should have an appropriate An electrical ground system should have an appropriate current-carrying capability in order to serve as an current-carrying capability in order to serve as an adequate zero-voltage reference leveladequate zero-voltage reference level..

Signal Ground is a reference point from which that Signal Ground is a reference point from which that

signal is measured.signal is measured. Chassis ground is the box or frame in which Chassis ground is the box or frame in which

a circuit is built. a circuit is built.

GROUNDINGGROUNDING

TERMINALSTERMINALS

A device for joining electrical circuits together

A A terminalterminal is the point at which a is the point at which a conductorconductor from an from an electrical component, device or network comes to an end electrical component, device or network comes to an end and provides a point of connection to external and provides a point of connection to external circuitscircuits ..

A A screw terminalscrew terminal is a type of is a type of electrical connectorelectrical connector where a where a wirewire is is clampedclamped down to down to metalmetal by a by a screwscrew . .

TERMINALSTERMINALS

BusBar/ShortBarBusBar/ShortBar

A device used for Making Multi- Connection

In electrical power distribution, a busbar is a thick strip of In electrical power distribution, a busbar is a thick strip of copper or aluminum that conducts electricity within a copper or aluminum that conducts electricity within a switchboard, distribution board, substation or other switchboard, distribution board, substation or other electrical apparatuselectrical apparatus..

Busbars are used to carry very large currents, or to Busbars are used to carry very large currents, or to distribute current to multiple devices within switchgear or distribute current to multiple devices within switchgear or equipment.equipment.

Busbars are typically either flat strips or hollow tubes as Busbars are typically either flat strips or hollow tubes as these shapes allow heat to dissipate more efficiently due to these shapes allow heat to dissipate more efficiently due to their high surface area to cross-sectional area ratio.their high surface area to cross-sectional area ratio.

BusBarBusBar

PD overview