Chapter 6 INTRODUCTION: MCB and UPS

6.1 Fuse, MCB and their Requirement

Fuse is a safety device that protects the circuit from excess current. Fuse is a piece of wire sized to melt when current more than specific amount passes through it. It melts and opens the circuit. Fuses are rated in amperes, a measurement of electrical current flow. Higher the amperage rating, more current can flow through the fuse before it blows. Types of Fuses Plug Fuse These fuses are Semi-enclosed and re-wirable fuses. These can be rewired with fuse wire. Most buildings use these fuses for wall outlets and lighting. These fuses also dont hold many amps typically less than 15.

Fig 6.1.

Plug fuse

Cartridge Fuses These fuses are typically cylindrical in appearance, although they can be different lengths depending on the electricity needs. These fuses are capable of handling larger electricity currents and are used in a variety of circuits. Most cartridge fuses are rated up to 500 volts. While plug fuses only hold 15 or less amps, a cartridge fuse will hold up to 600 amps of electricity.

Fig 6.2.

Types of fuses

Basic Concepts of Electronics and Electrical The difference between a cartridge and plug fuse is the amount of time taken to melt the fuses metal element. Fuses that are time delayed are commonly referred to as slow blow fuses, take longer to melt. These type of fuses are less likely to trip due to momentary electricity overloads. For example, while turning on a high energy lamp the slow blow fuse wont blow from the initial excess of electricity. MCB (Miniature Circuit Breaker) A circuit breaker is an automatically operated electrical switch designed to protect an electrical circuit from damage caused by overload or short circuit. Its basic function is to detect a fault condition and interrupt current flow. Unlike a fuse, which operates once and then must be replaced, a circuit breaker can be reset (either manually or automatically) to resume. There are three main types of MCBs: 1. Type B trips between 3 and 5 times full load current. 2. Type C trips between 5 and 10 times full load current. 3. Type D trips between 10 and 20 times full load current.

Fig 6.3.

Different types of MCBs

Fuse/MCB Selection While selecting the correct MCB or fuse for usage, its role in both over-current protection, and shortcircuit protection has to be considered. Basic principles underlying are as follows. Nominal current rule: The nominal current of the fuse/MCB must be less than the current rating of the cable it is protecting. For example, a 32-amp MCB is suitable for a current of 30 amps in a 35-amp cable circuit. Tripping rule: A current of 1.45 times the nominal current must cause the device to trip in less than 1 hour. All modern devices meet this requirement except re-wirable fuses. These fuses normally require about twice the nominal current to blow them in one hour. Disconnection time rule: In a short-circuit condition; the fuse/MCB must trip in less than a specified short time. Double Pole MCB (The main switch): Double Pole MCB allows turning off and on the electric supply to home because this is the main operating switch to control electric supply. Immediately switch off the main switch in emergency i.e. in electric shock, fire or while working on main board. Multiple mains switch also can be used if there is more supply unit. Fig 6.4. Double pole MCB

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Basic Concepts of Electronics and Electrical Circuit Breakers Circuit breaker is a device which switches off and on electric supply at normal and abnormal condition. These are automatic protection devices in the Main switch board or fuse-box that switch off a circuit if they detect a fault. The size of the fuse and Circuit Breaker are similar, but it gives more and more protection. If it trips, its can be reset.

Fig 6.5. Circuit Breaker

6.2

Earthing

Need of earthing: A wire coming from the ground 2.5 to 3.0 meter deep from an electrode /a metal plate is called earthing. The earth potential is always taken as zero for all practical purposes. The electrical apparatus or machines when connected with earth attain zero potential and are said to earthed. Earthing is needed for following purposes: 1. To save human life from danger or shock or death, if any apparatus this becomes leaky. 2. To protect large building from atmospheric lighting. 3. To protect all machines fed from over head lines from lightening arresters. There are two types of earthing: 1. Plate earthing. 2. Pipe earthing. Plate earthing: In the plat earthing, looping earth wire is bolted tightly with the earth plate, which is made up of copper 60cm x 60cm x 5mm and placed 3 meter in the ground. Copper plates are found to be most effective earth electrodes and are not affected by soil moisture. They do not get rusted. But as its metallic value is very high, galvanized iron plates are preferred and usually used for normal work. The plate is kept with its face vertical and is so arranged that it is placed in an alternate layer of coke and salt for a minimum thickness of 15cm. The coke and salt decreases the earth resistance. It is to be taken care that plate, nut, bolt and wire must be of same metal (either galvanized iron or copper). Usually the earth wire is drawn through a GI pipe fitted with a funnel on the top through which salty water is poured in the pit of the earth plate time to time. In summer session when the moisture of the soil will decrease to a large extent. This increases the earth resistance. The conductivity (earthing efficiency) increases with increase of plate size and depth of embedding. It is only disadvantage that conductivity of

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Basic Concepts of Electronics and Electrical earth wire with the plate below the earth cannot be seen physically; hence it is misleading and some time result in heavy loss in case of fault.

Fig. 6.6: Schematic of Buried Copper Plate Picture

Fig. 6.7: Buried Copper Plate Picture

Fig. 6.8: Earthing plate interconnection

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Basic Concepts of Electronics and Electrical Pipe earthing: In this system of earthing a GI pipe of 38mm diameter and 2meter length is kept vertically in ground to work as an electrode but depth depends upon the soil conduction. There is no hard and fast rule for this. The earth wire is fastened on the top section of pipe with nut and bolts. The pit area is filled with salt and coal mixture for improving the soil condition and efficiency of the earthing system. The contact surface area of GI pipe with the soil is more in comparison to the plate because of its circular section and hence can take up heavy leakage current for the same electrode size. The earth wire connection can be check up as the connection wire is above the ground level. It is an advantage over the plate type earthing. Advantage of Earthing: Earthing to equipments and apparatus provides effective safeguard against injury and death. Earthing saves the human life from danger or shock or death if any apparatus which becomes leaky. Earthing provides safety to the large building from atmospheric lighting. Earthing provide safety to all machines fed from over head lines from lightening arresters. Earthing provide very low resistance to the flow of heavy current to a circuit. Earthing to equipments and apparatus provides effective safeguard against injury and death. 6.2(b) Continuity and Resistance Test of earth All appliances are subject to this particular test, which ensures that there is a satisfactory connection between the Earth pin in a plug and the case of the appliance. The earthing of an appliance means it is safer to use because the chance of electrical shock is reduced, and combining these together with standard insulative properties enhances the safety of an appliance even further. This particular test is also referred to as an Earth Bond or Earth Resistance test, but they all measure the same thing. There are generally two types of earth bond test current used. Low current which is generally in the range of 100 to 200 milliamps. High test currents in the range of 10 amps or 25 amps. The earth bond test passes a test current along the earth cable from the pin of the plug to the bodywork of the appliance. The appliance tester then measures the resistance of that connection. If the connection is rusty, or corroded then the earth resistance reading will increase. To perform an earth continuity test, the appliances mains plug must be inserted into testing device and a test lead must be connected to a suitable earth point on the appliance. In order to pass the test, the reading from the tester should show that the resistance that has been measured is less than 0.1 + the resistance of the supply cable. Physical nature of the earth resistance: The understanding of the earth resistance physical nature will help us to evaluate the conditions to be fulfilled in order to get its correct measurement. According to its definition, resistors have two terminals and its resistance is defined as the quotient of the voltage applied on those terminals and the current circulating between them as a consequence of that voltage. The value of the resistance depends on the type of material (resistivity) and its physical dimensions (area and length of the resistive element). In the earth resistance, only one of the terminals is evident that is a electrically accessible part of a buried electrode in the earth resistance. And the second terminal is any other point of the earth. The idea is that outside the earth volume next to a buried electrode, through which a current is injected, all the planet volume is equipotential related to that current. Any point of that equipotential volume can be considered as the second electrode of the earth resistance.

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Basic Concepts of Electronics and Electrical Testing earth electrodes The earth electrode, where used, is the means of making contact with the general mass of earth. Thus it must be tested to ensure that good contact is made. There are several methods for measurement of the earth electrode resistance. In all cases, the electrode must be disconnected from the earthing system of the installation before the tests commence. Using an earth fault loop impedance tester The tester is connected between the phase at the origin of the installation and the earth electrode under test.The test is then carried out, the result being taken as the electrode resistance although the resistance of the protective system from the origin of the installation to the furthest paint of the installation must be added to it before its use to verify that the 50 V level is not exceeded. The protective system resistance is likely to be negligible by comparison with the permissible electrode resistance.

Fig. 6.9: Wiring for MCB and Cutout

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Basic Concepts of Electronics and Electrical It is most important to ensure that earthing leads and equipotential bonds are reconnected to the earth electrode when testing is completed 6.2 Switch, Junction and Outlet boxes

An electrical junction box is a container for electrical connections, usually intended to conceal them from sight and deter tampering. A small metal or plastic junction box may form part of an electrical conduit wiring system in a building, or may be buried in the plaster of a wall, concealed behind an access panel or cast into concrete with only the lid showing. It sometimes includes terminals for joining wires. A similar container used for joining wires to electrical switches or sockets is called a pattress.

Fig. 6.10: Junction Box

Fig. 6.11: Junction Box Wiring There are varieties for plastic and metal boxes. These boxes are in different shape and sizes such as, round, square and octagonal boxes. And they come in depths ranging from 1/2" to over 3" deep. Then there are boxes with no back that serve as depth extenders and covers with cut-outs for various uses. Electrical wall and ceiling boxes can be used in many ways, such as: Join or splice wires together in circuits Mount and house connections for a lamp fixture to a wall or ceiling Mount and house connections for a ceiling fan. Mount recessed in a wall or ceiling or surface mounted NIELIT, Chandigarh Centre
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Basic Concepts of Electronics and Electrical 6.4 Wiring and Testing 6.4.a. Inverter Wiring and Testing Always connect the inverter to a three pin, three-wire grounding mains socket. The socket must be connected to appropriate branch protection (fuse / circuit-breaker). To switch off the inverter output in emergency, use inverter RESET switch on the Front panel, also disconnect the mains cord. Avoid installing the inverter in open, excessively humid places or where there is possibility of water. Care must be taken to ensure that the inverter is kept away from heat-emitting appliances such as a heater, blower, oven etc. The unit must also be placed in a manner that it avoids exposure to direct sunlight. The place of the installation should be well ventilated and easily accessible for servicing. Foreign objects and water must not enter the inverter. Always ensure that no objects containing a liquid are kept near the unit (Inverter). Keep away from reach of children. Installation procedure: Identify the points, which are to be connected to the inverter. Ensure the appliances, which are to be provided with backup; do not exceed the capacity of the inverter. Consider the best suited position for the inverter installation as per all the necessary precautions. a. Mobile installation/connection With your battery bank connected the inverter, the input terminal is plugged into 15 Amp socket. An adaptor/extension is then plugged into the output terminal and appliances can then be connected to the adaptor/extension.

To various household circuits connected only to utility power To various householdcircuits connected both utility & inverter

Fig. 6.12: Mobile Wiring Mobile Interconnection b. Distribution Board (DB) installation/connection With the battery bank connected to the inverter, the input terminal is connected to the Mains power in the Distribution Boards (DB). The output terminal is connected to the relevant Miniature Circuit Breakers (MCBs) within the DB in which inverter to run. These MCBs can be separated.

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Basic Concepts of Electronics and Electrical

To various household circuits connected only to utility power

To various household circuits connected inverter Fig. 6.13: Installation of Inverter 6.4.b. UPS Wiring and Testing Purpose This wiring circuit diagram is design for when one want to give supply to particular rooms in the home or office in the building in case of failing the power supply. And power supply is needed continuously to the appliances (laptop, computer etc) in that specific rooms or office in case of low wattage UPS or single battery or in case of when generator system is not available. How to do this wiring in Home First of all, remove those Live (Phase) wires from the main distribution board (from the circuit breaker) of those particular Rooms (As shown in Figure) if one wants to give automatic supply (in both cases from Battery and Power House without any interrupt or disturbance). Suppose it is needed to connect only these two rooms with this system as shown in figure. Then connect these two live (phase) wires at the end as shown in figure. Now do the same wiring (Connect UPS, Battery, Home appliances etc) as shown in figure. both utility &

Fig. 6.14: UPS Wiring Interconnection NIELIT, Chandigarh Centre

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Basic Concepts of Electronics and Electrical

PRACTICAL COMPETENCY
6.1 (A) AIM: Testing and wiring of MCBs and fuses. Testing of MCBs.

APPARATUS: Multimeter, screwdriver set. Theory & Procedure Open the electrical box which contains the circuit breaker panel The switches are marked with the parts of the house to which they are connected. Before testing the circuit breaker, all the home appliances should be turned off and then unplugged. It prevents a short circuit which might result from an increase in the voltage. The multimeter is to be set to the position 'Volts AC'. Use two probes of multimeter, the first one to touch the terminal screw of MCB and the other one for the ground. If there is no indication in multimeter the MCB is bad, if there is indication then MCB is good. MCB can be tested for load also. For testing of load of MCB , disconnect the one end of the cable and connect it with the meter in series and other end of the meter with MCB. Verify the rated current of MCB with the reading of meter. (B) AIM: Testing of Fuse APPARATUS: Multimeter. Theory & Procedure Switch off the power supply of the equipment for which fuse is to be tested. Use analog/digital multimeter check the fuse. Select the multimeter in lowest ohms range(X1). Touch the probes of multimeter to both end of the fuse. The fuse can be checked while it still in circuit. If meter reading is Zero ohms or it continuity then fuse is working. If meter reading is not Zero ohms or it does not show continuity then fuse is not working. For fuse replacement, use only the fuse for same current ratings. 6.2 AIM: Find the total load and select a suitable UPS/Inverter(rating factor) for home use

Calculating Power Requirements The power required by a component is commonly called in either Watts (W) or Volt Amps (VA). The Watt and VA levels differ (the VA rating will always be equal to or higher than the W rating). The ratio of W to VA is called the Power Factor. In a resistive load such as a heater or a toaster, Watts and VA numbers are the same. Some devices will use a Power Factor Corrected power supply. These units will have a Power Factor almost equal to one (~0.99). These components typically include servers, hubs and storage systems. This means that a 1000VA rated component will have a 990W load. The capacity of UPS systems is given in Volt Amps. If the power consumption is not stated in Watts or VA, then check for the current consumption in amps (A). Multiply Amps by Input Volts to obtain the power consumption in VA. For example if a machine has a stated current consumption of 1.5A at 230V then power consumption will be 230 x 1.5 = 345VA. Once it is calculated and specified, select a UPS that will properly handle a particular load. To increase the battery runtime/backup additional batteries has to be added. NIELIT, Chandigarh Centre

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Basic Concepts of Electronics and Electrical Lets take another example: We have four computers that need to be given a UPS backup. Then if, one computer consumes 350 VA, then total power will be 350* 4 = 1400 VA. So the UPS needed will be of more than 1400VA . UPS is available in 500VA , 1000VA, 2000VA and so on. Hence UPS rated with 2000VA (2KVA) will be suitable . 6.3 AIM : Installation of UPS/Inverter.

Procedure: First of all the circuit/load to be connected on UPS/Inverter is to be identified and calculated UPS/Inverter rating Disconnect the Live(Phase) wires from the main distribution board of those particular circuits. Then connect these two Live wires at the end as shown in the figure.

Live wire to different desired circuits to be connected

Fig 6.15. Wire connections with UPS

on UPS

Fig. 6.15: Wire Connections with UPS

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