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3.1 METHODOLOGY
(lines from utility are open) and the voltage relay closes the contact to the
timer (few minutes to warm) and to the starter circuit of the engine for the
starting of the generator after few minutes. The timer contact will close,
thus energizing the main magnetic coil of the generator contactor to the
load. Upon sensing supply again from mains, the normally open contact
and time in the timer (few minutes); normally open contact latches and
energizes the mains contactor coil for the closure. The neutral and life wire
of the main supply is connected to the normally open of the contactor, the
neutral and life wire of the generator is connected to the normally close of
STARTER SOLENOID
RELAY STARTER
MOTOR
overall design is first broken into functional blocks as shown in the above
block diagram.
= 12 x 103 x 0.8
= 9.6KW
P = 3 IP VP cos Æ
IP = 9600 = 18.19A
3 x 220 x 0.8
IP ≈ 18.3A
100
= 18.3 + 4.6
= 18.3 + 9.15
= 37.45Amps
However, if the operating environment is very hot, a larger cable size will
be required.
(Maximum allowable
Since 234Ω resistor is not standard, 250Ω resistor was used as the closest
That is
The value of diode used in full wave bridge rectifier circuit was 1N4001
because it has voltage rating of 50V as required by the circuit. The rating is
also chosen to avoid any damage to the diode in case of reverse operation
occurs.
54mA respectively.
d. Filter capacitors
R = Diode resistance =?
Since 288μF capacitor is not standard, 330μF capacitors were used as
expression
However, the same calculation is also done in second voltage divider stage
SWITCHING UNIT
b. Base Resistance
In this case, since the resistor is also for the same purpose, the
Where:
(4.2)
Two circuit breakers of different ratings are used here. The first will be for
the power (Generator) circuit and the second for the control circuit. The
breaker to be used for the power circuit must have a rating of more than
15A. For this design, a 30 Amps 4 pole (3-phase) circuit breaker will be
used. For the control circuit, the breaker to be used will be a 6Amps single
pole breaker. This is because the current in the control circuit is measured
in mA
Contactor Design
Relay Design
Relays with the following parameters were used for the design:
Conductor Design
(4.3)
mains and generator contactors. It was observed that with the selector
Switch on the mains side in the ON position, the mains contactor was
energized immediately. When the selector switch was turned to the OFF
with the selector switch on the generator side in the auto position. When
Mains was restored by switching, the mains selector switch back ON, and
that the generator has started, the cranking signal is terminated and a fail
to start indication is given. Under these conditions, the fuel solenoid signal
soldering iron, lead sucker, long noise pliers, cutting pliers, screw driver,
tweezers. The appropriate tools were used to carry out the construction
differently in order to avoid the damage of the tools or any materials used
The construction of the circuit was carried out taking into considera
tion all components that are very sensitive to heat or that can be damaged
when they are over-heated. Also, those components that consume very low
CASING
consists of different parts which were fitted into each other to form an
enclosure for the regulating circuit board and the supporting components.
The casing has three dimensions: the length (1ft), the breadth (1ft) and
the height (5inch). The casing is ventilated because the power drawing in
the circuit is high. A stand of about 4cm is mounted on the edge of the
the project was assembled. Assembling was done by fixing the circuit
board into the casing and screwing properly to prevent vibration. It was
ensured that the enclosure was not too small for the board so as to
components.
SAFETY PRECAUTIONS
getting damaged.
TESTING:
test before the project will be satisfied okay. In production chain it will be
3. System testing.
as to remove the bad ones. This test will be satisfied test measures for
SYSTEM TESTING
This involves the testing of the entire circuitry and cross examines it
for errors like short circuits, lead flux, joining unwanted links. Proper
insertion of IC pin layout and also checking if ICs of these pin number are
slotted in their proper base. After the first check you should cross check
RESULT
generator.
Table 4.1
EEDC 22OV
GENERATOR 230V
The testing and result obtained above show that; output voltage from the
generator is greater than the output voltage from the mains. The above
observation shows that there is always a drop in voltage from the nominal
value. This voltage drop is as a result of the number of relays that comes
and power circuit. The power circuit has two main contactors controlling
both the Mains and the generator power. The control section of the
transfer switch is the main brain of the whole circuit. When there is no
supply from the Mains, the main contractor is disengaged (lines from utility
are open) and the voltage relay closes the auxiliary contact to the timer
(few minutes to warm) and to the switching circuit of the engine for the
starting of the generator after few minutes. The timer auxiliary contact
closes, thus energizing the main magnetic coil of the generator contactor
to the load. Upon sensing supply again from Mains, the auxiliary normally
generator contactor and time in the timer (few minutes). The normally
open contact latches and energizes the Mains contactor coil for the closure.
Interlock is provided to ensure that the Mains contactor and the generator
contactor under no condition will the two come on at the same time. The
generator contactor only comes on when the Mains fails, but with the
entire safety requirement for its safe operation. After the construction of
the control system the following important test was carried out:
Testing
opened contact.
tested by closing the contacts and using continuity tester to test for
continuity. When the protective devices such as the three phase line
hazards.
3.8.3. INTEGRATION
The integration of the units that made up the circuit and testing
them now as unified system. Here if the project is not working as assumed,
3.9. PACKAGING
project and maintenance factor which need may arise. There are some
1. Metal packaging
2. plastic packaging.
RESULT
generator.
Table 4.1
EEDC 22OV
GENERATOR 230V
The testing and result obtained above show that; output voltage from the
generator is greater than the output voltage from the mains. The above
observation shows that there is always a drop in voltage from the nominal
value. This voltage drop is as a result of the number of relays that comes
The transfer switch comprised of two different sections; the control circuit
and power circuit. The power circuit has two main contactors controlling
both the Mains and the generator power. The control section of the
transfer switch is the main brain of the whole circuit. When there is no
supply from the Mains, the main contractor is disengaged (lines from utility
are open) and the voltage relay closes the auxiliary contact to the timer
(few minutes to warm) and to the switching circuit of the engine for the
starting of the generator after few minutes. The timer auxiliary contact
closes, thus energizing the main magnetic coil of the generator contactor
to the load. Upon sensing supply again from Mains, the auxiliary normally
generator contactor and time in the timer (few minutes). The normally
open contact latches and energizes the Mains contactor coil for the closure.
Interlock is provided to ensure that the Mains contactor and the generator
contactor under no condition will the two come on at the same time. The
generator contactor only comes on when the Mains fails, but with the
Results
entire safety requirement for its safe operation. After the construction of
the control system the following important test was carried out:
Observation
mains and generator contactors. It was observed that with the selector
switch on the mains side is in the ON position, the mains contactor was
energized immediately. When the selector switch was turned to the OFF
with the selector switch on the generator side in the auto position. When
mains was restored by switching the mains selector switch back ON, the
for phase lost where a phase is removed, causing a failure to occur, hence
relay. If after five seconds no indication is received that the generator has
Output readings
Cost analysis
The labor cost = total man-hours utilized * number of days * rate per
hour.
= N5280.00
= 508.00 + 528.00
= 1,036.00
=1,036.00 + 103.60
=N 1,139.60
The current cost of three phase 40 amps automatic change over switch
with over voltage andunder voltage check device in the local market is
N35000.00
transfer switch ischeaper and the materials needed for replacement are