INDUSTRY: ELECTRICAL

TRADE: ELECTRICIAN

CLASS: ONE

TRADE TEST QUESTIONS

QUESTION

1 A bag stacker runs in two directions and is interlocked to a conveyor drive which runs
only when the stacker is in forward direction .The conveyor drive motor has a provision
for starting and running independently when the bad stacker is off.

 The bag stacker to show by an indicator when it is in reverse.

 The conveyor belt should be stopped from running when the bag stacker is being
reversed (use interlocks).
 Use interlocks to start up the conveyor when the bag stacker is running in forward
direction of rotation.
 The conveyor to show by an indicator lamp when it is running.

DRAW THE CONTROL AND POWER CIRCUIT AND THEN WIRE AS PER
DRAWN DIAGRAMS.

2 Draw schematic diagrams (control & power) for a four motor crane. The following
operations should be included.

 During long travel; hoist or auxiliary can be operated but the cross travel cannot be
operated.
 During cross travel; auxiliary or hoist should be operational but the long travel cannot be
operated.
 During Hoist operation; auxiliary cannot be operated but the cross travel can be operated.

DRAW CORRECT, FUNCTIONAL; CONTROL AND POWER CIRCUIT AND THEN

WIRE THEM

3 The mixer feed belt motor runs first, followed by 30hp crusher motor. The crusher motor
is followed by a crusher feed motor which runs automatically 5 minutes after the crusher.
The mixer feed and the crusher are manually operated.

 All the 3 motors are stopped by one local stop button

 An emergency stop button is incorporated in circuit for all motors.
 An indicator for each motor to show run connections.
 Interlock the motors to satisfy the conditions of the starting sequence.
4 Two short conveyor belts alternate to feed a long conveyor belt. Short belt 1 feed long
belt when it is in the forward direction. Short belt 2 feed long belt automatically 10
seconds later after it is being reversed.

 Long belt and short belt 1 are manually operated.

 An emergency stop to be incorporated to switch off long belt and short belt motor 1 and
short belt 2 when needed.
 Long belt to show a trip by indicator lamp.
 Short belt motors to show indicator when in run and stop condition.
 Long belt motor is star connected and two short belt are connected in delta.
 Short belt motors are interlocked such that one motor runs at a given time and only when
long belt is running.

DRAW THE CONTROL AND POWER CIRCUIT DIAGRAMS AND WIRE AS PER
DRAWN DIAGRAMS

5 A short screw feeds an elevator, elevator feeds a conveyor belt.

 The motors are interlocked.

 The elevator motor runs only when the conveyor is running and the short screw starts
automatically one minute later after the elevator motor has started.
 The short screw motor runs when the elevator motor is switched on.
 The elevator motor control to include an inch and change over switch for normal and inch
start.
 The elevator motor to be connected in delta (not star delta).
 All motors to indicate their running positions by means of indicators.
 The elevator to show by means of indicator its trip and off position.
 The short screw control circuit to include a manual start button that may be used in
emergency when timer fails.
 All motors to be stopped by one button.
 The elevator and conveyor motor control circuits to include one emergency stop button.

DRAW THE CONTROL AND POWER CIRCUIT and WIRE THEM

6 M2 should start 4 seconds after M1.

 If M1 is stopped or trips, M2 should stop.

 M2 should be prevented through interlocks from running while M1 is Bing reversed.
 M1 is a 20hp motor.
 Use one timer for control circuit
  Lamps to show power on, motor running and tripped.

DRAW THE CONTROL AND POWER CIRCUIT AND THEN WIRE PROPERLY

7 Grinding mill motor is controlled by an automatic star delta starter and is interlocked to a
steel belt conveyor.

 The conveyor motor is controlled by a direct on line starter.

 The steel belt conveyor has a manual start button for normal starting and another button
for inching. This button is used when the belt is being inspected or repaired.
 The steel belt conveyor should be started for normal running only when grinding mill is
in delta.
 The inching circuit should operate when grinding mill is switched off.
 Use a change over switch to wire circuits.
 Grinding mill to show indicator in delta.
 Conveyor to show indicator when running.

DRAW THE CONTROL AND POWER CIRCUIT AND WIRE THE CONTROL AND
POWER CIRCUIT

8 Three 5hp 380v conveyor motors are to be sequentially started.

 Conveyor motor C is to run first then B then A.

 If C develops a fault, all motors stops.
 If A develops a fault, only A stops.
 A & B are started direct on line.
 Motor C is star delta.
 All motors can run independently using inching buttons for the purpose of maintenance.

DRAW THE CONTROL AND POWER CIRCUIT AND WIRE THE CONTROL AND
POWER CIRCUIT

9 A crusher uses hydraulic jacks for loading its rollers

 The crusher motor can run when the hydraulic oil pump is running.
 If the oil pump trips, both of them trips.
 The oil pump can continue running when the crusher trips or stopped.
 The crusher motor changes from star to delta after 20 seconds.
 The oil pump is direct on line delta.
 Indicator lamps to show crusher and oil pump running.

DRAW THE CONTROL AND POWER CIRCUIT AND WIRE THE CONTROL AND
POWER CIRCUIT
 *the circuit to be wired as per the drawn diagram.

10 Two pumps A & B are arranged in such that pump A feeds B on its discharge.

 Pump A is started manually and B starts automatically 10 seconds later.

 Pump B can be stopped manually and restarts after 10 seconds later if A is still running.
 Pump A has a provision of manual starting in case of the automatic system fails.
 Pump B cannot start if A is out of service.
 Pump A trips if B does not run on auto or manual after 20 seconds of starting.
 Pump motor A is wired in star delta while B is direct on line delta.
 If any one of the 2 pumps trips, both come out of service.
 Indication lights to show the pump in service.

DRAW THE CONTROL AND POWER CIRCUIT and WIRE THE CONTROL AND
POWER CIRCUIT.

11 A system has 3 conveyor belts A, B & C.

 Conveyor A feeds B, B feeds C.

 The belts are manually started or stopped.
 Conveyor C has to run for B to run & B have to run for A to run.
 The three belt s can be inched independently of each other f or m maintenance
purposes.
 If any of the belt s is manually tripped locally, all belt s stops.
 The motors are in star delta a with 10 seconds delay on change over.

12 Two motors are arranged to operate automatically as long as their control and power
circuits are supplied.

 Motor A starts to run after 5 seconds of power supply establishment and stops after
30seconds.
 Motor B starts 5 seconds of motor A stopping and the cycle continues with A
restarting after 5 seconds of B stopping.
 The motor continues to run until supplies are cut.
 Both motors are run in star delta with 15 seconds changeover delay.
 Indicator lamps to show running motors.

13 Sand is fed manually into the elevator. The elevator t hen feeds a conveyor belt that
off loads into rail wagons.

 Both motors are operated manually.

 The elevator motor to be connected in delta and runs only when the conveyor belt
is on.
  The elevator motor control to include inching but ton and a change over switch f
or nor m al and inch starting.
 Both control circuits to include indicators for run/ on.
 The elevator to show by separate e indicators its trip & off posit ion.
 Both motors to be stopped by one stop button.
 Emergency stop buttons to be included for the elevator and conveyor motor.

DRAW THE CONTROL AND POWER CIRCUIT

14 A steel shaping machine with 15hp 380V 50 Hz has 2 modes of operation; Local and
Remote.

 When LOCAL is selected, the motor is to run in the forward direction and indicates
when in full speed.
 When REMOTE is selected, the machine is to jog in both forward and reverse direction.
 When remote is selected, the machine cannot start locally.

15 On a printing machine, the load tray which contains sheets of papers is raised up by a
3KW, 380V, 8.2A motor which runs for 10seconds and then stops automatically.

 Upon stopping, it engages a 35HP 380V 45A motor connected to a belt which pulls
sheets of paper from a load tray for 5 minutes and then stops.
 Upon stopping, it also engages the 3KW 380V 8.2A motor to run bit now in the reverse
direction until the machine is stopped.
 A provision should be made for momentary reversal of the machine in case of paper jam
on the belt being drawn by a 35HP motor.
 Show trip indications on the 35HP motor.

DRAW THE CONTROL AND POWER CIRCUIT AND WIRE THE CONTROL AND
POWER CIRCUIT

16 A corn milling plant has the following processes.

 A safety siren sounds first for 10 seconds and followed by main milling motor which is
controlled by an automatic star-delta.
 Granular motor starts automatically 10 seconds after the main motor is in delta.
 A feed conveyor motor starts automatically 10 seconds after granular motor.
 The dust extractor fan runs automatically 5 seconds after conveyor motor.
 The dust extractor fan has a provision for manual starting even if the conveyor motor is
not running.
 The process stops if any of the motors trips on overload.
 One stop button to be used.
 DRAW THE CONTROL AND POWER CIRCUIT AND WIRE THE CONTROL AND
POWER CIRCUIT

17 Three motors are to pump water from the reservoir.

 Pumps are manually operated and are D.O.L.

 The motors are interlocked such that at any given time, any 2 pumps should operate
whilst one is stationery.
 If any pump trips, the operation of the plant should stop.
 One indicator lamp to show that the circuit has tripped.
 Each motor to show running condition by a lamp.

DRAW THE CONTROL AND POWER CIRCUIT AND WIRE THE CONTROL AND
POWER CIRCUIT

18 A processing plant is operated by 2 motors which run as long as the circuit is powered.

 The motors are controlled by star-delta which has a 10 seconds delay.

 The first motor is to run within 10 seconds of power supply and run for 60 seconds.
 The second motor is to run 10 seconds after stopping the first motor and will also run for
60 seconds and stops.
 The process is restarted with the first motor.
 The process will stop when the power supply to the circuit is switched off.

19 A 30HP 380V motor is used to drive a pump situated 1000 meters away from the tank
house.

 When the tank is full, the pump set de-energised automatically.

 When the tank is low, the pump set energised automatically.
 When the tank is low, a siren is given before set energised automatically.

DRAW THE CONTROL AND POWER CIRCUIT AND THEN WIRE THEM

20 A mine operation requires a following operation on one of its processing plant which uses
a 3phase 1kw induction motor with specifications

 Speed -1440 rpm; Voltage- 400v; Frequency-50Hz.

 On starting the motor, it runs in the forward direction for 15 seconds and stops
automatically.
 The motor is required to be idle (stopped not running) for 20 seconds to allow the motor
to be still.
 After 20 seconds the lapse (motor being still) it is required the motor runs in the reverse
direction.
 a) Design power and control circuit
b) List the correct size of materials to be used for this project
c) Wire the circuits.

21 A heavy concrete rolling is run by a drip proof 3 phase induction motor, which has the
following specifications:

 Voltage- 400v, power- 40kw, speed- 940rpm and slip 0.04.

 At starting the above plant stated should run in the reverse direction for 20 seconds.
 After running 20 seconds in reverse direction it must stop automatically for 30 seconds to
motor to be still.
 Automatically after 30 seconds of motor being still (not running) it must run in the
forward direction.
 Motor runs in the forward direction automatically without initiating any start button ( ie
no forward start button).
 Motor should run in forward direction continuously until stop button is initiated.
a) Draw power and control circuit.
b) list the materials required
c) wire the circuits

22 Draw schematic diagram for sequential of 2 motors with the following starting operation.

 Motor 2 starts 20 seconds after Motor 1.

 If either motors stops or is overloaded or develops a fault both motors should stop.
 Motor 2 is prevented through interlocks from running while motor 1 is being reversed.
 Motor 2 runs in star delta and motor 1 in direct online forward and reverse (motor to stop
when motor 2 is running in delta).
a) Draw power and control circuit.
b) List the materials required
c) Wire the circuits

23 Waste matter is to be pumped from a pit using two 5kw, 380v, 12.4A, 3000rpm using
sump pump motor and float switches.

 Pump A runs when the pit is 40% - 100% full.

 Pump B runs when the same pit is 70% - 100%
a) Draw power and control circuit.
b) List the materials required
c) Wire the circuits

24 A mixer motor runs first, then a crusher motor.

 A crusher motor is a 30Hp which runs on star-delta.

  The crusher feeder motor then runs automatically after 5 minutes of a crusher motor.
 The mixture and the crusher feeder motors are manually operated and are star connected.
 One stop will stop all the motors. One emergency stop button incorporated to protect all
the motors.
a) Draw both power and control circuit to satisfy above operation.
b) Interlocks should be included so that the operation of the motor is as stated.

25 The water that supplies Rindall farm is pumped into a reservoir tank 2m above ground
surface. It has been discovered that the water pressure in the water reticulation is low.
This has resulted in some areas of the farm not receiving water. It has also made it
difficult to carry out irrigation in areas that are at long distances from the reservoir. It has
been suggested for irrigation purposes, a water pump with the following requirements
must be used.

 A 3HP motor is to be used for irrigation.

 The irrigation should be started both locally and remotely (ie at the tank and from the
farm house).
 The irrigation pump should shut down and not start when water in the tank is less than
40% full.

An indicator panel should be installed to indicate:

a) Irrigation pump running.
b) Low water level (when less than 40% full).

26 A sheet pressing machine has a hydraulic pump which is driven by a 1.5kw, 3 phase
induction motor. The hydraulic pump pre lubricates gears on the drive before the main
drive is introduced.

 The main drive consists of a gear box driven by a 20kw screen protected, 415v, 3 phase
induction. Specifications
 At starting the hydraulic pump runs.
 20 seconds after starting the hydraulic pump, the main drive should run automatically.
 When running the main drive is running, a lamp is to be lit to indicate press running.
 When either the hydraulic pump or the main drive develops a fault both motors should
stop.
 The circuit is also to incorporate a remote emergency stop button at the control room.

27 Three conveyor motors are to be run sequentially and manually operated starting with
motor C then B and finally A.
  Motor B and A should not run unless motor C is running.
 Motor A should not run unless B and C are running.
 If motor C develops an overload both motors should stop
 If motor B develops an overload motor Band A should stop
 If motor A develops an overload only motor A should stop.
 All motors run in DOL.

28 On a printing machine, the load which contains sheets of paper is raised by a 3kw, 380v,
3 phase-8.2A motor for 10 seconds and then stops automatically.

 Upon stopping it engages a 35hp which pulls the sheets of paper from the load tray for 5
minutes then stops.
 Upon stopping it automatically engages the first 3kw, 380v, 3 phase motor to run again
but now in the reverse direction until the machine is stopped.
 A provision should be made for momentary reversal of the machine in case of a paper
jam on the belt being driven by 35hp motor.
 In case of an overload a pilot lamp should come on.
 Include remote switching and an emergency stop in your circuit.

29 Induction motor. The hydraulic pump pre - lubricates gears on the drives before the main
drive is introduced. The main drive consists of a gear box being driven by a 20kw screen
protected 415V, 3 phase induction motor.

 At starting the hydraulic pump runs.

 20 seconds after starting the hydraulic pump, the main drive should run automatically.
 When the main drive is running, a lamp is to be lit to indicate press running.
 When either the hydraulic pump or the main drive develops a fault, both motors should
stop.
 The circuit is to also incorporate a remote emergency stop button at the control room.
a) Design schematic control and power circuit for this project.

30 After 10 seconds elapse; Motor A and Motor B are to run in the reverse direction. Both
motors are to stop at the same time in case of overload, emergency stop or by a stop
button.

 Draw power and control circuit diagrams.

 Order and mount the correct size of equipment.
 Five regulations pertaining the installation you wired.
 Overload setting.
31 An industrial machine has two motors, a lubrication pump and a work piece turning
motor.

 The pump motor is controlled by a direct on line (D.O.L) Forward and Reverse Starter.
 The work piece turning motor is controlled in one direction by a star - delta starter.
 The work piece turning motor is automatically energized 10 seconds after the direct on
line (D.O.L).
 Motor runs in the clockwise direction only.
a) You are required to design and construct a starter circuit for this machine.

32 Moulding cups and pots operates with motors. Motor A is the Oil pump,

 Motor B is the moulder and Motor C is the water sprayer.

 All the motors are direct on line (D.O.L)
 Motor A should run first before any other motor.
 Motor B should be able to run forward and reverse
 Motor B should not reverse when motor C is not running.
 Motor B should be stopped first before reversing.
 All motors to be started manually using start buttons.
 Use one stop button for stopping the machine.
a) Design control and power circuits that satisfy the above.

33 when the bag stacker is in forward direction.

 The conveyor belt motor two (M2) and the bag stacker motor one (M1) to show by means
of an indicator when it's in forward direction.
 The conveyor belt motor two (M2) not to run when motor one (M1) is being reversed.
 Use interlocks to bring motor two (M2).Only when motor one (M1) is in forward
direction.
 The conveyor drive to have a provision for starting and running independently when the
bag stacker is off.
 The conveyor to show by an indicator when its ON.

34 interlocked.

 The elevator motor runs only when the conveyor motor is running.
 The short screw starts automatically one minute (1 min) later after elevator motor has
been started.
 The short screw motor runs when the elevator motor is switched ON.
  The elevator motor to include an Inching button and a changeover switch for manual
starting and Inching.
 The elevator motor to be connected in Delta.
a) Show running position of motors by indicators and trip respectively.
b) The Short Screw Circuit to include a manual start button that may be used in emergency
when timer fails.
c) All motors to be stopped by one push button.
d) The elevator and conveyor motors to include the emergency stop button for each.

35 A grinding can run in forward and reverse directions.

 When running in forward it will enable a conveyor belt to be started independently.

 The conveyor is used to load bags of mealie meal from the grinding mill.
 The method of starting the grinding mill is a star delta and a conveyor uses direct on line
(D.O.L).
 The grinding mill should show when running in reverse by an indicator lamp.
 The conveyor has a changeover switch which will enable us to jog, run the motor in order
to position the bags.
 The conveyor should show when not being jogged.
a) Draw the control circuit to satisfy this.

36 Three motors wired sequentially A, B, C.

 If C develops a fault all motors should stop.

 if B develops a fault motor B and A should stop
 if A develops a fault only A stops.
 C is wired in star delta and A in (D.O.L)
 The other motor can also be operated manually individually in inch circuit. (For
maintenance).

37 In a manufacturing company, a conveyor belt is used to ferry quarry from crushing

machine to a storage shade. A 25Hp, 3 phase induction motor is used to drive the belt.

 Before the belt is driven, a siren should sound, first for 5 seconds, then automatically the
induction motor starts driving the belt.
 The motor then runs for 2 minutes and then stops automatically and De-energies the
whole circuit.
 A provision should be made for momentarily reversal of the belt in case of a jam
occurring.
 An emergency stop is required in the circuit.
 Run and stop indicators should be included in the circuit.
38 An ore crashing plant has three conveyors that move ore from the ore pit to the crusher.
The plant is arranged that the conveyors are started and stopped sequentially so that
overloading the conveyor is prevented. Ore should be loaded on a conveyor that is
moving and not stationary hence the need to interlock them in the control circuits.

 The sequence for starting is [3] then [2] then [1].

 The sequence for stopping is [1] then [2] then [3]
 If [3] trips;[2] & [1] must stop automatically through interlocks.
 If [2] trips;[3] can go without stopping.
 [1]Cannot start without [2] & [3] running.
 [2] Cannot start without [3] running.

39 A grinding mill is to be driven by an 11kw, 380v, 3 phase electric motor and is fed by a
driven by a 3kw electric motor.

 The mill motor is to be reversed using an inch button when the mill jams and is also
protected by thermistors.
 The conveyor should not run until the mill inching.
a) Prepare the power % control circuit for this particular mill.

40 A grinding mill is controlled by an automatic star delta starter & interlocked to a steel
conveyor belt.

 The conveyor belt is controlled by a D.O.L start button for normal starting & another
button is used when inching
 When this is being inspected or repaired the steel belt should be started for normal
running only when the grinding mill is switched off.
 Grinding mill should show by indication when it is in delta.
 Steel belt should also indicate when running normal.

41 A mine hoist is to be wired in such a way that upon raising to the surface it must over
shoot to the headgear direction.

 It should allow movement only in the direction opposite to that it had before tripping
 indicators for power ON up direction & down direction and overload trip ore to be
indicated.

42 Two short conveyor belts alternate to feed a long conveyor belt.

 Short belt # [1] feeds a long belt when t is running in the forward direction.
 Short belt # [2] feeds long belt automatically 10 minutes later when it is reversed
 Long belt & short belt # [1] are manually operated.
  An emergence stop button is in the circuits to switch OFF long & short belt # [1] or
long& shorts belts # [2] when they are a need.
 The long belt motor should show an indicator its trip condition.
 The long belt motor is star Y connected while the # [1] & # [2] (short conveyor belts)
motor are delta ∆ connected.
 The two short belt motors must not run @ the same time & should run only when long
belt motor is running.

43 The market garden section consists of two major sections :The vegetable and the grains
section, for watering the garden is pumped from a reservoir tank using two
10kw,380v,50Hz 3 phase induction motor controlled by a float switches.

 Watering starts when the tank is 100% full.

 When the water level drops to 75%,The vegetable would have been watered adequately,
hence the pump watering that section stops.
 The pump watering the grain section continues & stops when the water level has fallen to
10%.

44 The stock feed processing plant consists of a grain crushing mill which is to be driven by
a15kw, 380v, 50Hz 3phase induction motor.

 The grain is feed into the mill by a conveyor belt system which is supported to a3kw,
380v, 50Hz 3phase induction motor.
 The conveyor runs ON when the mill is operating at full speed.
 The mill jams occasionally during operation hence a circuit should be provided for the
mill motor to clear the system.

45 The garage section has two major projects the compressor & the pillar drilling machine.
The conditions for operations for the compressor are as follows;

 The air compressor is driven by a 20Hp motor which is connected to 380v, 50Hz, 3phase
supply.
 Before the compressor can be started a water pump & air pump must be started in order
to supply coolant to the compressor.
 If the water pump fails, the compressor motor must stop also so does the air pump failure.
 The compressor motor is also protected against high pressure & high temperature
conditions.
 There is also a blower which cools the compressed air before it gets into air receivers.

46 A water pump driven by 30Hp motor is cooled by external fan of 3Hp motor which
switches ON when a machine attains its full speed. Under normal situation;
  When the water level goes below the required level, the machine will automatically
switch ON
 It takes one hour to fill the tank to the maximum level and then it will automatically
switch OFF for the maintenance sake.
 The machine can be started & stopped locally despite the water level & the machine
cannot be started remotely during maintenance.
 In case of automation failure, the machine can start & stop manually on remote.

47 An air compressor is driven by 20Hp motor which is connected to a 550v supply & drove
22A.

 Before the compressor motor can be started, a water pump& oil pump must be started to
supply the coolant for the compressor.
 If the oil pump fails the compressor must trip out as the same as it does if the water pump
fails.
 The conveyor is also protected against high pressure &high temperature condition.
 The power circuit is D.O.L
a) Draw a control circuit that including the protection & interlock mentioned above.

48 A lathe is driven by a 7Hp 380v motor.

 Before the motor is started a water pump & oil pump is started first to supply lubrication
to the lathe.
 If the water pump or oil pump fails the lathe must trip out.
 The lathe motor is protected against high temperature conditions among usual
protections.
a) Draw the control & power circuit for the project.

49 A 12Hp motor 16,5A 380v is to run a high pressure reservoir pump.

 Water level in the reservoir must not fall below ¼ full & must not overspill.
 Pump must operate below 4 bars pressure.
 Upon starting in the auto or manual the siren must sound for @ least 20 seconds to alert
& allow the pump attendant to operate safe valve.
 For safety of protection against accommodation of moisture in the starter must not run if
the panel door is open.
 An indicator must show pump in run & in stop mode.
 Overload trip condition must be shown by way of light & siren.
 However upon acknowledgement of trip on overload, A button must cancel the siren but
the light indication must remain ON until reset.
 Remote switching of the starter must be enabled.
 An energy ammeter /volt must be incorporated. Design circuit.
50 Two separate pumps A & B both of size 7½Hp-380v-12,6A are controlled by two
separate float switches A & B.

 Float A runs @ 40% full.

 Float B takes over @ 75% .
 If the refuse tank is filling fast for
 Float B stops pump B when the tank is below 75% full & float A stops pump A when the
tank is below 40% full.
a) Design power & control circuits for the above situation.

51 A 90Hp motor is to drive a milling crusher,

 When it is running it indicates by a green light.

 However it has a provision of inching in reverse when it joins.
 It incorporates a conveyor belt when it is running & when it stops the conveyor stops
automatically.
a) Design a power circuit, a control circuit and order materials that you would require.

52 Design a circuit that has local & remote control system.

 The local control runs the circuit continuously & remote is for jog.
 The local control runs the circuit both directions, so as the remote.
 When the local control is on, the remote should not come in so the remote when it is in,
the local should not come in.
a) Design a control circuit to meet the above.

53 A 15Hp machine motor is to be run in forward when controlled locally and must indicate
when in full speed.

 It is also to jog in the forward & reverse direction when controlled in remote.
 When controlled in remote it should not start locally.
 A light must indicate when motor is in full speed forward direction.
a) Design power & control circuits.

54 Design a circuit that runs continuously/normal running in forward & jog in reverse.

 When normal running @ its full speed, the provision should be provided to allow the
feeder conveyor belt into motion, but the conveyor belt should have a separate start- stop
switch.
 When the main circuit trips the whole circuit should stop but when the conveyor belt
stops, the main circuit should continue running.
 When the circuit is reversed, the conveyor belt should not come in. design the circuit
above.
55 A lathe machine 10Hp motor consist of a star delta forward & reverse starter which runs
continuously under normal circumstances.

 To cater for job settings the circuit has a provision for jog/inching on both directions.
 Jogging can be achieved through the use of a relay contactor which can be switched on
independently.
 During normal operations the relay contactor will be out & during abnormal or dots
settings the relay will be opposite.
 To select jog the machine should be switched of first.
a) Design control & power circuit to achieve the above conditions.
b) Show clearly all your interlocks needed for the circuit to operate properly.
c) Order the required material & wire the above project.

56 A cage rotor induction motor is to be started D.O.L and have both FORWARD &
REVERSE control to the following specifications:

 One stop button stops the motor when running in either direction.
 It must have low voltage & overload protection.
 Interlocking must prevent FORWARD/REVERSE circuit to be simultaneously
energized.
 Before reversing the direction of rotation the motor must be allowed to rest being
energized in the reverse direction

57 2 motors are to run; one must be in FORWARD/REVERSE.

 When the first motor is running in FORWARD, it must run for 20 sec and soon after 20
sec the second must run in Star/Delta.
 If the first motor is running in Rev, the second motor must not run.
 Safety measures should be incorporated so that when one motor develops a fault the other
one should not start or even run.

58 A conveyor belt has a motor which draws 1,2Amps and 380v.

 BEFORE the motor has started it must ring a siren for 8sec; thereafter the motor can be
started.
 If the motor is to be started 45sec after the siren stopped, starting will be inhibited.

59 Motor 2 is brought in by motor 1.

 Motor 1 is FORWARD &REVERSE and Motor 2 is D.O.L

 Motor 2 is running in FORWARD direction only.
  Motor 2 stops after 20min.
 In Motor 1 REVERSE, Motor 2 does not run

60 A grinding mill is driven by a 40hp-3 phase motor.

 The mill is fed by a constant rate conveyor.

 The conveyor is fed from a bin with a vibro-motor.
 The mill starts the conveyor and the bin runs after 5sec.
a) Design a power and control circuits taking into consideration components size selection.
b) All motor tests should be done before connection.

61 Design a circuit with a continuous running feeding conveyor belt.

 The conveyor motor is a 2hp motor, stacker motor is 5Hp motor

 It feeds a stacker which moves from left to right.
 It delays by 3sec @ each end.
 It runs automatically in both directions.
 It includes braking system.
 Once started by an operator it runs automatically till stopped.
a) Design power & control.

NB : Take into consideration breaker size, contactor size and overload setting for both
motor

62 A 5hp machine motor is to run in FORWARD when controlled locally and must indicate
when in full speed FORWARD direction.

a) Design power& control circuit

63 Design power and control for a local and remote control system.

 The local control runs the circuit continuously and remote is for jog.
 The local control runs the circuit both directions, so as the remote.
 When the local control is on the remote should not come so the remote when it is in, the
local should not come in.

64 Design an automatic transfer switch which separates ZESA power supply with generator
power supply

65 Two separate pumps A and B both of size 7.5hp-350v-12,6A are controlled by 2 separate
float switches A &B.

 Float A runs @ 40 full of float B takes over @ 75%

 If the refuse tank is filling fast for float B stops pump B when the tank is below 75% Full
  Float A stops pump A when tank is below 40% full.
a) Design power &control

66 A 12Hp motor 16,5A is to run a for high pressure reservoir pump,

 Water level in the reservoir must not fall below ¼ full and must not overspill.
 Pump must not operate below 4 bars pressure,
 Upon starting in the auto or manual the siren must sound for @ least 20sec to alert and
allow the pump attendant to operate safety valve
 For safety of protection against accommodation of moisture, the starter must not run if
the if the panel door is open.
 An indicator must show pump in run & stop mode
 Overload trip condition must be shown by way of light and siren,
 However upon acknowledgement trip on O/L, a button must cancel the siren but the light
indication remains ON until reset by an electrician
 Remote switching from a plan to an away from starter must be enabled.
 An energy ammeter/volt must be incorporated
a) Design power & control circuits

67 Design a circuit for a 15kw motor which runs in the FORWARD & REV direction which
when stopped should stop after 20sec in the forward direction only and in reverse should
stop instantly

68 Design a circuit for a washing machine which runs 20sec in the forward direction then
stop for 5sec & then run in the reverse direction for 20sec and stop for 5sec & run in the
Forward direction.

69 A milling machine motor have controlled fully by auto Forward & Reverse controlled by
limit switches, specifications for the control circuit are below:

 One stop button must stop the motor when running in either direction
 O/L and low voltage protection is given to the motor
 Electrical interlocks prevents simultaneously energizing of both FORWARD AND
REVERSE @ the same time
 Selective FORWARD AND REVERSE starters must be provided for starting between
limit switches position
 Describe a suitable control circuit for the motor

70 Design a circuit for a crane with a 4kw motor which moves the load up and down. A
1,5kw motor which moves either left or right. Specifications for the circuit are:

 One stop button which must stop both motors

 If one motor trips it must not affect the other motor
  A crane can’t go left/right sides when it is moving up/down
 All motors must be started by inching or jogging to reach the required level
 Limit switches are used to stop motors when reaching max level
 Every motor must have indicators which indicates direction it is running

71 Design a circuit for a 2kw motor which goes to the Forward & stops for 10sec offloading
and then goes back to the original position. Specifications for the control circuit:

 One stop button

 Indicators which indicates direction
 limit switch on delay timer

72 Design a control circuit of a D.O.L starter comprising the following:

 3 stop buttons
 6 start with one local button but when it stops, the motor should stop after 10sec

73 Design a circuit for a 5kw motor when it trips on O/L a siren rings and pump attendants
should come and stop the siren & call the Electrician.

 The pump must not reset by pump attendants

 A 2kw motor is incorporated which starts running if the main motor starts to run for
30sec

74 Design a circuit which would engage 3 motors into operation @ intervals of 10sec
starting with the last motor within the line of operation of the 3 motors

 If only one of them experienced a fault or an O/L, all should stop.

 The motors should be switched @ the same time.

75 3 motors are to be used on conveyors as follows:

 All motors start 5sec apart & must have the starting sequence

76 An 11kw-380v-3 phase grinding mill is to be used on the mentioned m/c.

 It is protected by thermistors
 When the mill jams, it is reversed by an inch reverse mechanism.
a) Draw reverse and control circuit to show the above illustration and wire them.
b) Make suitable ordering of components or motors needed

77 Design a circuit for a 15kw motor which when stopped stops after 10sec

78 Design a circuit for a 15kw motor which runs in the FORWARD direction & REVERSE
direction, which when stopped should stop after 10sec in all direction
79 Air compressor is to be driven by a 15kw/20hp motor which is connected to a 550v
supply & draws a current of 22Amps, before the compressor motor can be started, a
water pump & an oil pump must be started in order to supply coolants before the comp

 If the water pump fails, motor must stop also & so does the oil pump failure
 The comp is also protected from high pressure & temps conditions
 There is also a blower which cools the comp air before it gets in the air reservoir
 Prepare a control and power circuit for the above mentioned project

80 The conveyor belt system load trucks at constant rate with material being dumped at a
point A & transferred from belt until it arrives @ end B.

 The 3 belts are driven by separate motors M1, M2, M3 which must operate according to
the following specifications:
 One push button starts all motors in sequence M3, M2& M1 to ensure any previous load
to be transferred before addition on extra load.
 An O/L on any motors stops all the motors
 One stop button stops all the motors in the sequence M1, M2& M3 to get rid of the last
load

81 Sequential starting of 2 motors A & B.

 Motor A runs on D.O.L and Motor B runs on star/delta

 Motor A should start Motor B after 10sec.

82 A grinding mill is controlled by an automatic star/delta starter and is interlocked to a steel

belt conveyor.

 The belt motor is controlled by D.O.L starter.

 The steel belt conveyor has a manual start button for normal starting and another button
for inching.
 This button is used when the belt is being inspected and repaired.
 The steel belt conveyor should be started for normal running only when the grinding mill
is in delta.
 The inching circuit should operate when the grinding mill is switched off.
 Use a changeover switch and interlocks to wire the circuit.
 The grinding mill should by an indicator when it is in delta.
 The steel belt conveyor should also show by an indicator when it is in normal running

83 Given a 25hp-50Hz 3phase motor.

 Design a starter that when start button A is pressed, Motor runs in one direction
continuously
  When B is pressed the motor runs in one direction but in star mode while jogging

84 A grinding mill is to be driven by a 3 phase motor and is fed by a conveyor driven by a

3kw motor.

 The grinding mill motor is to be reversed using an inching button when the grinding mill
jams
 It is also protected by thermistors.
 The conveyor should not run when the grinding is inching

85 Given a 25hp-550v-3phase.

 Water goes into sewage through gravity when the sump is full.
 Motor runs until a certain empty level is reduced then automatically stops.
 The cycle repeats.
a) Design the control and power circuit

86 Motor2 should start 10sec after Motor 1.

 If either motor develops a fault or O/L, both motors should stop.

 Motor 2 runs in star/delta and motor 1 in D.O.L
 Motor 1 to stop when motor 2 is running in delta

87 Water is to be pumped out of pit by 2 motors rated 5.6kw-380v-2.4Amps.

 Pump A and B are connected by a float switch.

 Pump A should pump water in the pit @ 40% to 100% full while B should also pump
water @ 25% to 100% full

88 4 motors are to be used, 2 oil pump motors and 2 hydraulic motors to feed a big
compressor 20kw motor.

 The motors are to be wired in such a way that the big motor is not energized until all the
4 motors are in full swing.
 The main compressor motor is controlled by a low pressure and high pressure switch.

89 A compressor motor is controlled by a star/delta starter which uses local and remote start-
stop button

 When the motor starts on load a siren should be sounded.

 The operation should be able to cancel the siren only and all the shift electricians to
attend the fault first and then reset the circuit.
90 From a 380v-3 phases; 4 wire & earth system are required to:

 Design a circuit show how you would connect the three phase motor on your panel to run
in star configuration when the start button is operated.
 The status of the motor must be indicated by the pilot lights on panel ,e.g. motor “ON”
and motor “OFF”

1 horsepower = 745.6999 watts

1 horsepower = 0.7457 kilowatts

Power = √3 VL IL CosФ