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AMF PANEL FOR DG SET

CONTENTS
CHAPTER 1:- INTRODUCTION
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1.1 OBJECTIVE
1.2 INTRODUCTION TO AMF CONTROL PANEL
1.3 FEATURES OF AMF CONTROL PANEL
1.4 COMPARISION OF EXISTING AND
PROPOSED SYSTEM

CHAPTER 2:- AMF PANEL COMPONENTS


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2.1 LIST OF AMF PANEL COMPONENTS
2.2 AMF RELAY
2.3 CONTACTORS
2.4 MCB
2.5 SWITCHES
2.6 BUZZER
2.7 PUSH BUTTION
2.8 INDICATOR LAMPS
2.9 REMOTE RELAY UNIT
2.10 SHEET ENCLOSURE SHEEL
2.11 WIRING ACESSORIES

CHAPTER 3:-OPERATION OF AMF PANEL


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3.1 CIRCUIT DIAGRAM OF AMF PANEL
3.2 OPERATION OF AMF PANEL

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CHAPTER 4:-INSTALLATION OF PROJECT PICTURES


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4.1 MAKING OF PROJECT
4.2 PHOTO GALLERY

CHAPTER 5:-ADVANTAGE & APPLICATION


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5.1 ADVANTAGE OF AMF CONTROL PANEL
5.2 APPLICATION OF AMF CONTROL PANEL

CHAPTER 6:- COSTING


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6.1 COSTING

CHAPTER 7:-RESULT, CONCLUSION & BIBILOGRAPHY


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7.1 RESULT OF PROJECT
7.2 CONCLUSION
7.3 BIBILOGRAPHY

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1
CHAPTER: 1
INTRODUCTION

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1.1 OBJECTIVE:

Electricity is an essential commodity in our day to day life.


Electricity forms the basics of any developing country or a developed
country. Electricity is required in industries and commercial purposes.
Thus electricity is very important failure in electricity supply or
interruption in the supply may cause adverse effect. In the event of any
failure of main supply the standby power should come in line without
any time delay. For meeting this requirement an automatic Mains Failure
(AMF) arrangement is required for automatically changing over from
utility supply to DG supply in the event of utility supply failure.

The main objectives of the system are:


1) Design a system that allows switching from mains power to
backup power when anomaly is detected.
2) Design an automatic system using Relay Operating Control
system.
The installation of AMF panel as a huge scope, because this system
provide more flexibility in respect to wastage of fuel and time. The AMF
panel makes the DG set to turn on immediately and avoid an interruption
of supply and switches of the DG set immediately the main power arises
which saves the fuel. And these system increases more efficiency and
this system are easy to operate.

1.2 INTRODUCTION:
The main idea of this project work is to highlight the economical
impact of excessive diesel consumption of Diesel Generators (DGs),
reliability issues, lack of flexibility of operation, inadequate sizing of
DGs, overworking of Diesel Generators (DG) owing to the negligent
attitude of the electricians, improper location of DGs in the electrical
Layouts, operation with load limitation as constraints and in turn
develop an amicable solution to resolve such issues. These critical
problems are addressed in this project by designing an Automatic Mains

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Failure scheme (AMF) for practical implementation with proper sizing


of DG taking into consideration the present connected loads, optimum
location for DG with due considerations for connected loads, short
circuit rating, rated thermal rating and neutral sizing of all cables and
conductors associated with this captive power plant. An extensive work
is carried out to study the connected loads in order to arrive at proper
sizing of the DG set in order to totally remove the load constraints and to
ensure economical, reliable and uninterrupted operation of the
Generator. Presently, the DG sets are manually switched on in the event
of Mains failure. Number of Generators and capacity of the Generator
need to be manually brought into operation will have to be based on
prevailing load requirements at the instant of power failure. Hence the
need for an AMF control panel is implemented.

First phase of our project is oriented toward the development of an


AMF circuit and fabrication of a demo unit as per the designed AMF
circuit. Subsequently the AMF unit is put into operation by interfacing
with a laboratory alternator and utility mains supply. The sequence of
various operations is practically tested at the laboratory level.

As a second phase, a practical circuit is developed for real time


interfacing with a load and utility supply.

The third phase is to study and incorporate an overall real time


practical circuit, for automatic starting of DG set, monitoring all the
required mechanical parameters of associated Diesel Engine with
necessary interlocks, in this project work. This project ensures the
removal of stress on manual switching of Generators when the mains
supply fails.

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1.3 FEATURES OF AMF PANEL:


The main features of AMF control panel are as follows:-

 The AMF control panel prevents the wastage of fuel by


automatic switching on DG set and automatic switching off
the DG set.

 Automatically starts the DG set when Mains fail.

 Automatically stops the DG set when Mains restore.

 Automatically changes the lines from Main AC to Gen Line


and vice versa.

 Total controlling by Remote switch.

 Fails- to -start alarm Start Delay Time 3 seconds.

 6 no’s PBs for control operations.

 2 digit seven segment display for parameter setting and time


countdown indications

 16 no’s. LEDs to indicate plant status.

 Automatic Battery Charger inbuilt in AMF unit.

 Auto / Manual mode selector available.

 5 no’s of alarm for LLOP, HWT, V-BELT, LFL, LOW


BATTERY.

 Stop solenoid action.

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 Main restore delay time 10 seconds.

 Total control of safety on DG.

 Generator cranking Relay & Harness are inbuilt.

 By use of remote relay voltage loss can be avoided.

 The proposed system operates in both automatic and manual


mode.

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1.4 COMPARISON OF EXISTING SYSTEM


AND PROPOSED SYSTEM:
Present day AMF panel cannot be controlled from a distance, however
in the proposed system a remote relay unit which works as a Wi-Fi
module which is one of the prominent feature incorporated in the AMF
relay, the AMF panel can be controlled from a distance.

Present day AMF panel uses a resistive sensor in order to measure the
fuel level in D.G set and can also start the DG set immediately when
utility fails. The resistive sensor is simply a wire which is dipped in the
fuel tank. The resistance of the wire changes in accordance to the fuel in
the tank.

The use of resistive sensor can create sparks which can pave the way for
large fire hazards. With the use of a sensor in the smart AMF panel, that
risk is totally eliminated. Industries always appoint a person, who is in
charge with AMF panel room and its control. But in this system, manual
supervision is not needed, since the system is fully automatic. Present
day AMF panel uses a resistive sensor in order to measure the fuel level
in D.G set. The use of remote relay unit can avoid voltage drop, and
gives pulse to start the DG set.

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2
CHAPTER: 2
AMF CONTROL PANEL
COMPONENTS

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2.1 LIST OF AMF PANELCOMPONENTS:

 AMF RELAY

 CONTACTOR

 4 POLE MCB

 2 and 6 POLE SWITCHES

 RYB INDICATOR LAMPS

 BUZZER

 INDICATOR LAMPS

 12 VOLT BATTERY

 REMOTE RELAY UNIT

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2.2 AMF RELAY:

 INTRODUCION OF AMF RELAY

Auto Mains Failure Relay ( AMF Relay) from is an unique solution for
stand by DG set installations where users need automatic start / stop of
DG sets and changeover of power connections to load from EB supply
to DG supply and vice versa.

AMF Relays are designed with latest micro-controller technology and


provide the users with hassle free operation of their DG sets both in
automatic mode and manual mode.

The relay, in addition to carrying out the DG start / Stop and power
change over functions, monitors vital engine parameters and ensures
safety of the diesel engine.

TECHNICAL SPECIFICATIONS:

 Micro-controller based design.


 96 x 96 DIN Standard bezel size, Small depth behind panel.
(Less than 80 mm)
 2 digit seven segment LED display for Time settings.
 16 status indicator LEDs.
 Vital engine parameters monitoring
 Special contact for Ignition Circuit.
 Auto / Manual operation.
 6 adjustable settings for timers and stop solenoid operation.
 Battery voltage monitor
 Status alarms

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WIRING OF AMF RELAY

There are a total of 21 terminals to be wired.

ER, EY, EB, EN EB Line voltage inputs ( 240V AC L-N)

DN, DR DG R phase Input (240 V AC L-N)

LLOP, HWT, BLT, LFL DG Fault inputs from DG set sensors.

B+, B- Station Battery supply

IGN Coil signal to external Relay to close


ignition circuit of DG set

STR Coil signal to external Relay to Start DG set

STP Coil signal to external Relay to Stop DG set

NC Not Connected\

ALM, ALM Potential free contact for external alarm relay

DGR, DGR Potential free contact for external DG


contactor coil supply

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ER EY EB EN DN DR LOP HWT LFL BLT

B- B+

AMF RELAY

EBR EBR DGR DGR ALM ALM NC STP STR IGN

SERACON

Front Panel controls / Indications :

The front panel of AMF-01 has the following;


a) 6 no’s PBs for control operations
b) 2 digit seven segment display for parameter setting and time
countdown indications
c) 16 nos. LED’s to indicate plant status.

Control Push Buttons :

There are 6 no’s PBs which helps the user to do the following:

PROG: When this PB is pressed, the unit enters into Program mode -
in this mode the user can alter the time delay and operational settings.

The Automatic/Manual Push-button and the RESET Push-Button


will act as increase / decrease buttons when in Program mode.

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Automatic/Manual: The relay is always in auto mode by default. When


this Push-Button is pressed the relay enters into manual mode. In manual
mode the user can select the manual operation of the DG set and the
contactors.
If pressed while in manual mode, the unit goes to Auto mode.

RESET: When pressed this will cancel an alarm situation. First press
will de-energize the alarm relay and make the flashing alarm LED to
become steady on. Second press will switch of the alarm LED, provided
the alarm condition is removed. If alarm is still present at the time of
reset, the sequence will repeat.

EB-RLY: This acts as a push button and effective only in manual mode
and only if EB supply is present. When pressed, it will switch on EB
contactor if it is off and switch off EB contactor if it is on.

DG RLY: This acts as a push button and effective only in manual mode
and only if DG supply is present. When pressed, it will switch on DG
contactor if it is off and switch off DG contactor if it is on.

DG SET: This acts as a push button and effective only in manual mode.
When pressed, it will start DG set, if it is stopped and if EB supply is
absent. If the DG set is already on, the PB actuation will send stop signal
to the DG set.

Two digit Seven Segment LED’s:


These are meant for;

 Display of set parameters during programming the relay.


 Count down of time during auto mode operation.
 Display of supply status/fault status

16 No’s individual LED’s:


 DG START: This will come on when the unit gives a Start pulse.
 DG STOP: This will come on when the unit gives a Stop pulse.

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 ALARM: This will come on when there is a DG set fault.


 LOBAT: This will come on when the battery voltage goes below
11V for 12V model and below 22V for 24 V model.
 HWT: This will come on when the cooling water temperature is
high.
 LLOP: This will come on when the lubricator oil pressure is low.
 LFL: This will come on when the fuel level is low in the tank.
 V-Belt: This will come on if the coupling V belt is loose.
 AUTO: This will come on when the unit is in auto mode.
 MANUAL: This will come on when the unit is in manual mode.
 EB: This will come on if all three phases of EB supply are on.
 EBR: This will come on when the EB contactor signal is on.
 DG: This will come on if the R phase of DG supply is on.
 DGR: This will come on when the DG contactor signal is on.
 START FAIL: This will flash when there is a DG start fail- will
become steady after first reset, will go off after second reset.
 STOP FAIL: This will flash when there is a DG stop fail- will
become steady after first reset, will go off after second reset.

Parameter Programming:
The user can set various parameters listed below with the help of
the front panel PBs.

Parameter Description Range Default


Value
Timer T1 EB on to EBR on 1 – 10 sec 5 sec
Timer T2 EB fail to DG Start 1 – 10 sec 4 sec
Pulse
Timer T3 Start Pulse On time 1- 5 sec 3 sec
Timer T4 Stop pulse ON time 1 to 30 sec 10 sec
Timer T5 DG Idle Run time 1 to 5 min 1 min
EN Stop Solenoid Action 0=Energize 0
- can be set as 0 or 1 to stop
1= Energize
to Run

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CS EB FAILURE 0 = all 3 1
DEFINITION – phases fail
can be set as 0 or 1 1= any one
phase fail

Press Inc / Dec PBs to change value to 0 or 1.After required value is


reached, press PROG. Unit will exit PROG mode and come to auto
mode of operation. Value of CS is now stored in memory.

 WORKING OF AMF RELAY

AMF Relay is an electronic controller, used in AMF panels. AMF acts


as a central control to automate the DG set operations in any installation.

AMF monitors the utility EB supply. If EB is present, it provides signal


to make EB contactor ON so that the load is connected to EB supply.
Whenever the EB supply fails, the relay switches off EB contactor,
gives start signal to start the DG set. Once the DG set is started, the relay
switches on the DG contactor so that the load is now connected to DG
supply. The relay also provides a signal to close the ignition circuit of
the DG set, so that the battery charging circuit is complete. If the DG
does not start after a start impulse, the relay generates an alarm signal,
indicating that there has been a start failure.

If the EB supply returns, when the DG is running, the relay switches off
the DG contactor, switches on the EB contactor and gives stop signal to
the DG set.

If the DG does not stop after a stop pulse, the relay generates an alarm
signal, indicating that there has been a stop failure.
The relay also monitors the battery voltage and sensor inputs from DG
set (mainly LLOP, HWT, LFL and V-Belt) and shuts down the DG set
under any of these abnormalities. The alarm is in the form of a potential

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free contact (to which an external hooter can be connected) as well as a


flashing LED.

Whenever the unit is powered on, it goes into Auto mode by default. If
user wants to change time delay settings or operate the installation
manually, this can be done by the use of the front panel push buttons.

AMFRELAY
AMF RELAY AMF-01
AMF-01
ALARM AUTO

DG STR MANUAL

DG STP EB

LO BAT PROG A/M RESET EBR

HWT DG

LLOP DGR

LFL START
FAIL
EB RLY DG RLY DG SET
V BELT STOP
FAIL

SERACON
SERACON

AMF RELAY – Details of Operation


When powered on, the relay will enter into auto mode by default, sense
the plant status, and provide necessary outputs as required.

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Operation in Auto Mode :


The relay will look at various conditions in the plant and generate
required outputs as follows:

If EB power is on :

 EB LED will be on
 Seven segment (SS) display will show EB
 T1 timer delay will start count down on seven segment display.
 After T1 count down to Zero, EB relay will switch on EB relay
LED will come on.
 All LEDs on the left column will be off
 On the right column, LEDs Auto, EB and EBRLY will be on

If EB power fails :

 EB LED will go off


 EB relay will go off
 T2 timer delay will start count down on seven segment display.
 After T2 count down to Zero, Ignition relay will come on.
 DG start LED +relay will be on
 SS display will show DG
 After DG Start relay on, Timer T3 starts count down
 At the end of T3, DG starts LED + relay will go off. T3 defines
the start pulse duration. Before the start pulse is completed, DG
should have started.
 DG LED will come on
 SS display will show DG
 After the DG starts, DG relay will switch on after 2 sec (approx)

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If DG fails to start :

 In case the DG has not started after the start operation as above the
relay will indicate Start Fail
 SS display will show ST
 Start fail LED will flash
 The unit will get locked into this mode and remain in this mode for
ever till reset is done.

Resetting the Start fail condition :

 When start fail indication appears, press RESET


 The flashing Start Fail LED will become Steady on.
 Alarm relay will go off.
 Press RESET again – the steady LED will go off and the unit will
return to auto mode.
If EB power returns :

 EB LED will be on
 SS display will show EA
 DG relay will go off after 2 sec
 T1 timer delay will start count down on seven segment display.
 After T1 count down to Zero, EB relay will switch on.
 EB relay LED will come on.
 SS display will show EB
 Timer T5 will start countdown ( this is idle run time)
 At the end of T5, DG stop LED relay will be on
 Timer T4 will start countdown ( this is the stop pulse on time)
 At the end of T4 , DG stop LED relay will go off
 Ignition relay will go off

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If DG fails to stop :

 In case the DG has not stopped after the stop operation as above
the relay will indicate Stop Fail
 SS display will show SP
 Stop fail LED will flash
 Alarm relay will be on. The unit will get locked into this mode and
remain in this mode for ever till reset is done

Resetting the Stop fail condition:

 When stop fail indication appears, press RESET


 The flashing Stop Fail LED will become Steady on.
 Alarm relay will go off.
 Press RESET again – the steady LED will go off and the unit will
return to auto mode.

If there is a DG fault:

 The AMF relay accepts Battery negative signal as fault input, the
relay has provision to read 4 fault signals (HWT, LLOP, LFL and
VBLT).
 If any of these signals are present during DG running, the relay
will switch of the DG Set
 Alarm Relay will come on.
 The respective fault input LED will be steady on.

Resetting the DG fault condition:

 when any of four DG fault alarm comes on , press RESET


 The fault remains Steady on.
 Alarm relay will go off.
 SS display will show EF

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Operation in Manual Mode:


User can perform following operations manually, by selecting Manual
mode in the AMF relay.

To enter into Manual Mode (From auto mode): Press A/M PB

 SS display will show EB if EB is on, DG if DG is on and PM if


both EB & DG are off.
 Auto LED will go off, Manual LED will come on

To control EB Relay: (This is possible only if EB is present)


 Press EB RLY PB.
 EB relay will come on (only if EB supply is present) and if it is
already off.
 If the EB relay is already on the relay will go off when EB RLY
PB is pressed.

To control DG Relay: (This is possible only if DG is present)


 Press DG RLY PB.
 DG relay will come on (only if DG supply is present & EB supply
is absent) and if it is already off.
 If the DG relay is already on the relay will go off when DG RLY
PB is pressed.

To control DG SET:
 Press DG SET PB.
 If the DG is off, DG start relay will come on.
 The DG start relay will be on for the duration of the PB being
pressed. If the PB is released, the DG start Relay will go off.

To go back to Manual Mode:


 Press A/M PB.
 Auto LED will come on. Manual LED will go off.
 Unit will go to Auto mode and perform all functions automatically.

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2.3 CONTACTORS:

 INTRODUCTION TO CONTACTORS

A contactor is an electrically controlled switch used for switching an


electrical power circuit, similar to a relay except with higher current
ratings and a few other differences. A contactor is controlled by a circuit
which has a much lower power level than the switched circuit.
Contactors come in many forms with varying capacities and features. A
contactor is not intended to interrupt a short circuit current. Contactors
range from those having a breaking current of several amperes to
thousands of amperes and 24 V DC to many kilovolts. The physical size

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of contactors ranges from a device small enough to pick up with one


hand, to large devices approximately a meter on a side.
A contactor has three components. The contacts are the current carrying
part of the contactor. This includes power contacts, auxiliary contacts,
and contact springs. The electromagnet (or "coil") provides the driving
force to close the contacts. The enclosure is a frame housing the contact
and the electromagnet. Enclosures are made of insulating materials
like Bakelite, Nylon, and thermosetting plastics to protect and insulate
the contacts and to provide some measure of protection against
personnel touching the contacts. Open-frame contactors may have a
further enclosure to protect against dust, oil, explosion hazards and
weather.
A somewhat greater amount of power is required to initially close a
contactor than is required to keep it closed. Such a circuit can save a
substantial amount of power and allow the energized coil to stay cooler.
Economizer circuits are nearly always applied on direct-current
contactor coils and on large alternating current contactor coils.
A basic contactor will have a coil input. The coil may be energized at the
same voltage as a motor the contactor is controlling, or may be
separately controlled with a lower coil voltage better suited to control
by programmable controllers and lower-voltage pilot devices. Certain
contactors have series coils connected in the motor circuit; these are
used, for example, for automatic acceleration control, where the next
stage of resistance is not cut out until the motor current has dropped.
Contactors are used to control electric motors, lighting, heating,
capacitor banks, thermal evaporators, and other electrical loads.

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 WORKING OF CONTACTOR

As contactors are used for high-current load applications they are


designed to control and reduce the arc produced when the heavy motor
currents are interrupted. Other than the low current contacts, they are
also setup with Normally Open contacts. These are devices which handle
more than 20 Amperes current and over 100 Kilo Watt’s power The
contactor has an AC/DC supply driven coil input. This will depend on
the requirement. This coil will mostly be controlled by a lower voltage
PLC. They can also be controlled by the motor voltage. The motor may
have series of coils connected to either control the acceleration or even
the resistance.

When current is passed through the contactor, the electromagnet starts to


build up, producing a magnetic field. Thus the core of the contactor
starts to wind up. This process helps in energizing the moving contact.
Thus the moving and fixed contacts make a short circuit. Thus the
current is passed through them to the next circuit. The armature coil
brings in high current in the initial position. This reduces as soon as the
metal core enters the coil. When the current is stopped, the coil gets de-
energized and thus the contacts get open circuited.

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2.4 MCB:
 INTRODUCTION TO MCB
All fuses need to be replaced when they have operated. Unlike a
fuse, an MCB operates as automatic switch that opens in the event of
excessive current flowing through the circuit and once the circuit returns
to normal, it can be reclosed without any manual replacement. MCBs are
used primarily as an alternative to the fuse switch in most of the circuits.
A wide variety of MCBs have been in use nowadays with breaking
capacity of 10KA to 16 KA, in all areas of domestic, commercial and
industrial applications as a reliable means of protection.

An MCB or miniature circuit breaker is an electromagnetic device that


embodies complete enclosure in a molded insulating material. The main
function of an MCB is to switch the circuit, i.e., to open the circuit
automatically when the current passing through it exceeds the value for
which it is set. It can be manually switched ON and OFF as similar
to normal switch if necessary.

MCBs are of time delay tripping devices, to which the magnitude of


over current controls the operating time. This means, these get operated
whenever overload exist long enough to create a danger to the circuit
being protected. Therefore, MCBs doesn’t respond to transient loads

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such as switches surges and motor starting currents. Generally, these are
designed to operate at less than 2.5 milliseconds during short circuit
faults and 2 seconds to 2 minutes in case of overloads. A typical
external appearance of an MCB is shown in figure. MCBs are
manufactured in different pole versions such as single, double,
triple and four pole structures with different fault current levels.

Mostly, MCBs are linked to give two and three-pole versions


such that a fault in one line will break the complete circuit and
hence complete circuit isolation are provided. This feature will be
helpful in case of single phasing in three phase motor protection.

These are rated at 220V for DC supply and 240/415 for AC supply with
different short circuit current capacity. Typically, single phase devices
have load current range of up to 100 A. Some MCBs have facility to
adjust its tripping current capacity while some devices are fixed for
some load current and short circuit rating. MCBs are used to perform
many functions such as local control switches, isolating switches against
faults and overload protection devices for installations or specific
equipments or appliances.

 CLASSIFICATION OF MCB’S

Types of MCB based on Tripping Characteristics

 Type B MCB: This type of MCB trips between 3 and 5 times full
load current.

 Type C MCB: This type of MCB trips between 5 and 10 times full
load current.

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 Type D MCB: This type of MCB trips between 10 and 20 times full
load current.

Types of MCB based on Number of Poles

 Single Pole (SP) MCB: A single pole MCB provides switching


and protection only for one single phase of a circuit.

 Double Pole (DP) MCB: A two Pole MCB provides switching and
protection both for a phase and the neutral.

 Triple Pole (TP) MCB: A triple/three phase MCB provides


switching and protection only to three phases of the circuit and not
to the neutral.

 3 Pole with Neutral [TPN (3P+N) MCB]: A TPN MCB has


switching and protection to all three phases of circuit and
additionally Neutral is also part of the MCB as a separate pole.

 4 Pole (4P) MCB: A 4 pole MCB is similar to TPN but


additionally it also has protective release for the neutral pole.

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 WORKING OF MCB
Under normal working conditions, MCB operates as a switch (manual
one) to make the circuit ON or OFF. Under overload or short circuit
condition, it automatically operates or trips so that current interruption
takes place in the load circuit. The visual indication of this trip can be
observed by automatic movement of the operating knob to OFF position.
This automatic operation MCB can be obtained in two ways those are
magnetic tripping and thermal tripping.

Under overload condition, the current through the bimetal causes to raise
the temperature of it. The heat generated within the bimetal itself enough
to cause deflection due to thermal expansion of metals. This deflection
further releases the trip latch and hence contacts get separated. In some
MCBs, magnetic field generated by the coil causes develop pull on
bimetal such that it deflection activates the tripping mechanism.

Under short circuit or heavy overload conditions, magnetic tripping


arrangement comes into the picture. Under normal working condition,
the slug is held in a position by light spring because magnetic field
generated by the coil is not sufficient to attract the latch. When a fault
current flows, the magnetic field generated by the coil is sufficient to

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overcome the spring force holding slug in position. And hence slug
moves and then actuate the tripping mechanism.

A combination of both magnetic and thermal tripping mechanisms is


implemented in most of MCBs. In both magnetic and thermal tripping
operations, an arc is formed when the contacts start separating. This arc
is then forced into arc splitter plates via arc runner. These arc splitter
plates are also called arc chutes where arc is formed into a series of arcs
and at the same time energy extracted and cools it. Hence this
arrangement achieves the arc extinction.

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2.5 SWITCHES:
A switch is an electrical component that can break an electrical
circuit, interrupting the current or diverting it from one conductor to
another. The mechanism of a switch may be operated directly by a
human operator to control a circuit, may be operated by a moving object
such as a door-operated switch, or may be operated by some sensing
element for pressure, temperature or flow. A relay is a switch that is
operated by electricity. Switches are made to handle a wide range of
voltages and currents; very large switches may be used to isolate high-
voltage circuits in electrical substations.

 2.10 WHAT IS A SELECTOR SWITCH?

2 WAY SELECTOR SWITCH

Selector Switch works on a general principle; they contain a simple


selector switch on the front of the panel, and a broad range of potential
contact combinations (via the contact blocks), on the inside of the
enclosure. The major difference between the selector switch and the
pushbutton is that, while a pushbutton has a plate that pushes down both
contact plungers at the same time, a selector switch has a rotating cam

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with ridges and flats, allowing to actuate the plungers independently.


Selector switches are available in 2, 3, or 4-position versions, and are
often used when more than one control option is needed. In general, the
center position of the selector switch is the starting cam position. Left
position presses the left plunger in the selector switch. Turning the
selector switch to the right presses down the right plunger.

 WORKING OF WAY SELECTOR


SWITCH

Selector switches use cams in combination with contact blocks to


provide a wide range of circuit openings and/or closings. In the
following diagram, "X" designates a closed circuit (energized or "on")
for a particular selector switch position, and "O" to designate an open
circuit (not energized or "off")

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In the figures below, a 3-position selector switch is used to open or close


two circuits, "hand" and "auto", for a pump application. It works in the
following manner (reflects a left, center and right selector switch
position.

Indicating lights are part of selector switches. Setting a selector switch


is how we tell machines how to operate. Indicating lights tell us what the
machine is do or failing to do. When a light is connected to a machine
process, and the light is on, the machine shows that it's working.

Selector switches are used when more than one control option is needed
(e.g. Hand-Off-Auto). These switches are preferred when a maintained
contact is needed.

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2.6 BUZZER:

A buzzer or beeper is a signaling device, usually electronic, typically


used in automobiles, household appliances such as a microwave oven, or
game shows.
It most commonly consists of a number of switches or sensors connected
to a control unit that determines if and which button was pushed or a
preset time has lapsed, and usually illuminates a light on the appropriate
button or control panel, and sounds a warning in the form of a
continuous or intermittent buzzing or beeping sound. Initially this device
was based on an electromechanical system which was identical to an
electric bell without the metal gong (which makes the ringing noise).
Often these units were anchored to a wall or ceiling and used the ceiling
or wall as a sounding board. Another implementation with some AC-
connected devices was to implement a circuit to make the AC current
into a noise loud enough to drive a loudspeaker and hook this circuit up
to a cheap 8-ohm speaker. Nowadays, it is more popular to use a
ceramic-based piezoelectric sounder like a Son alert which makes a
high-pitched tone. Usually these were hooked up to "driver" circuits
which varied the pitch of the sound or pulse the sound on and off.

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2.7 PUSH BUTTON SWITCH:


A Push button (also spelled push button) or simply button is a
simple switch mechanism for controlling some aspects of a machine or a
process. Buttons are typically made out of hard material, usually plastic
or metal. The surface is usually flat or shaped to accommodate the
human finger or hand, so as to be easily depressed or pushed. Buttons
are most often biased switches, although many unbiased buttons still
require a spring to return to their un pushed state. Different people use
different terms for the “pushing” of the button, such as press, depress,
mash, hit and punch.

It is used in simple manual operations in which the machine or


process has no electrical circuits for control.

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2.8 LAMP INDICATORS:

A malfunction indicator lamp MIL), also known as a check engine


light,is a tell-tale to indicate malfunctioning of a computerized engine
management system. It is found on the instrument panel of most
automobile .when illuminated it is typically either anamber or red
colour. On vehicles required with OBD-11,the light as two stages:steady
(indicating a minor fault such a loose gas cap of failing oxygen sensor)
and flashing.

When the MIL(mal functioning indicator lamp) is lit,the engine


control unit stores a fault code relatec to the malfunction,which can be
retrived with a scan tool and used for further diagnosis. The mal function
indicator lamp usually besrs the legend CHECK ENGINE SERVICE
ENGINE SOON, or a pictogram of an engine. The MIL appears in the
early 80s along with computerized engine controls even the earliest
system. Such as GM”s CCC(computer command control)system had
self-diagnosis functionality. When the computer detected a fault, it
illuminated the MIL.

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2.9 REMOTE RELAY UNIT:

Remote relay unit consists of transformer,miniature power relay smallest


size 5A switching capacity relay,capacitors, resistors etc.

It is a unit used for starting a DG set which is usually placed on a DG


bed, which start the DG set only if any fault or EB supply fails. The
remote relay unit recieves a AC power but transformer converts it into
dc power, Which is stored by capacitor it powers the DG when EB fails.
The each relay as a separate function one relay to start the DG set and
other relay function is to perform the solenoid action.

The use of remote relay unit as many advantages which prevents from
voltages drop,avoids the uses of heavy gauge cable.

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2.10 SHEET METALLIC ENCLOSUE:

The product is made from stainless steel, fiberglass, painted mild steel,
polycarbonate and die cast aluminum. The enclosure is used for keep the
machines parts protected.
APPLICATIONS:
 The product can find the usage in various industries and factories.
The product is widely used for engineering and electrical
applications

AREAS:
 Telecommunications
 Computer storage

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 Medical
 Industrial equipment and machines

FEATURES:
 Prevent the enclosure from imploding under water pressure
 Applies the necessary compression on the silicon gasket
 Easy to install

SPECIFICATIONS:
 Our extensive equipment provides a large range of capabilities,
from small to large sizes
 Mild steel (cold rolled and hot rolled) to 5/8 thick
 Aluminum sheet up to 1/4 inch thick
 Stainless steel sheet up to 1/4 inch thick

ADVANTAGES:
 Can form complex shapes
 Many material options
 High production rate
 Low labor cost
 Short lead time possible

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2.11 WIRING ACCESSORIES:

Wiring Accessories is commonly understood to be


an electrical installation for operation by end users within a building, an
engineered structure or a designated outdoor location. It includes the
cabling and associated devices such as switches, distribution boards,
sockets and light fittings but does not cover the transmission of electrical
power to the installation.

Such wiring is subject to rigorous safety standards for design


and installation. Allowable Wires and cables types and sizes are
specified according to the circuit operating voltage and electric
current capability, with further restrictions on the environmental
conditions, such as ambient temperature range, moisture levels, and
exposure to sunlight and chemicals. Associated circuit protection,
control and distribution devices within a building's wiring system are
subject to voltage, current and functional specification.

To ensure both wiring and associated devices are designed, selected and
installed so that they are safe for use, they are subject to wiring safety
codes or regulations, which vary by locality, country or region.

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3
CHAPTER-3
OPERATION OF AMF
CONTROL PANEL

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3.1 CIRCUIT DIAGRAM OF AMF PANEL

 POWER WIRING DIAGRAM:

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 CONTROL WIRING DIAGRAM-1:

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 CONTROL WIRING DIAGRAM-2:

 CONTROL WIRING DIAGRAM-3:

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3.2 OPERATION OF AMF PANEL:


As said early the main objective of AMF panel is to provied the load
a supply without any interuption in supply.when the ac supply of 240
volts is passed through the circuit. To energize a relay a 12 volt dc
supply is used. The operation of AMF panel can be operated by
manual mode or automatic mode.The operation of AMF panel is
explained below.

 When the EB mcb is turned ON and at the same time the relay
is also energized, now the operation is in auto mode. The relay
indicates EB i.e EB load is present, and after a time delay of 4
seconds the EB contactor energizes and supplies power to the
load through EB supply.

 When the EB fails i.e the utility supply is cut-off the supply to
load is also cut-off.so DG must start, the relay gives the signal
to start the DG within the time delay of 2seconds the DG should
be switched ON, now the supply to load is fed from the DG
source.

 When the EB returns the relay senses the presence of EB and


gives signal to stop the DG set, at the point of time the DG
supply should be turned off and alow EB to supply power to the
load.

These is the ways that AMF panel can be operated.Now what all
the fault may arise when the DG is running and the load is
powered by a DG set. The different fault in DG set are.

LLOP,LFL,HWT & V-BELT

When these fault arises in the DG set the relay senses these faults
and indicates the DG to stop running. which also cuts the supply
to load

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4
CHAPTER-4
INSTALLATION OF
PROJECT PICTURES

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4.1 MAKING OF PROJECT:

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4.2 PHOTO GALLERY

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WHILE THE LOAD IS POWERED BY EB SUPPLY

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INDICATING THE DG SET FAULT

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5
CHAPTER-5
ADVANTAGES
& APPLICATION

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5.1 ADVANTAGES:

 It is very simple in operation.

 The construction of panel is simpler and easy to understand.

 Monitoring of EB and DG contactor fail.

 Necessary for uninterrupted electrical supply

 Ideal for efficiently switching to generator power

 Ideal for less accessible generators.

 Less maintenance.

 Saves the wastage of fuel.

 No unexpected system failures.

 No shutdowns due to capacity overload.

 Increased system life span.

 Assured personal safety.

 Cost effective.

 Takes less time to start the DG set.

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5.2 APPLICATIONS:

 Processing plants.

 Agriculture.

 Generators.

 Engineering units.

 Hospitals Offices.

 Synchronizing of more than one DG together.

 Paper manufacturing industries, for continuous supply of electricity.

 Industries.

 Colleges.

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6
CHAPTER-6
COSTING

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6.1 COSTING:

SL.NO DESCRIPTION QTY PRICE TOTAL


PRICE
1 4 POLE, 6A MCB 02 1100 2200
2 AMF RELAY 01 5000 5000
3 TWO WAY 01 192 384
SELECTOR
SWITCH(A/M)
4 SIX WAY SELECTOR 01 300 300
SWITCH(A/M)
5 MNX9, 3 POLE 02 622 1244
CONTACTOR
6 N/O CONTACT FOR 01 42 42
PB
7 N/C CONTACT FOR 01 42 42
PB
8 START PB 01 56 56
9 STOP PB 01 56 56
10 INDICATING LAMP 06 111 666
GREEN
11 INDICATING LAMP 08 111 888
RED
12 INDICATING LAMP 03 111 333
YELLOW
13 INDICATING LAMP 03 190 570
BLUE
14 WIRING ACESSORIES - 120 120
LUGS

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15 WIRING ACESSORIES - 100 100


TERMINALS
16 SHEET METAL - 2250 2250
SHEEL
17 NYLON BASE PLATE - 100 100
18 RRU+PSU - 900 900
19 POWER CORD - 100 100
20 TERMINAL STRIP - 150 150
21 1.5 SQMM COPPER 30 100 300
CABLE
22 STICKERING 01 100 100

TOTAL = 15,900/-

TOTAL AMOUNT:-

FIFTEEN THOUSAND AND NINE HUNDRED RUPEES


ONLY/-

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7
CHAPTER-7
RESULT, CONCLUSION
&
BIBILOGRAPHY

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7.1 RESULT:
The AMF was interfaced with utility and DG set. The utility
supply was switched off and AMF unit was found automatically cut in
and power supply was restarted to the connected load, through DG set.
And it switches from utility to supply to DG supply. With the use of this
system a wastage of can be attained with automatic changeover from DG
to utility supply. The DG receives pulse to start automatically when the
utility supply is disconnected from the load..In this case for
understanding we just shown in the form of indicators the change of
supply to load that is from EB to DG or DG to EB.

With the use of proposed system, a large amount of energy


wastage in the D.G sets can be solved. The energy wastage is very
crucial when the D.G set gets heated up with continuous usage. When
the situations of long run power failure occur, the D.G has to work
continuously with a large amount of energy wastage in the form of heat
in the present day system, where as in the proposed system, the idea of
multiple generators are entertained.

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7.2 CONCLUSION:
AMF panel is very significant in the present world, where uninterrupted
power supplies are at most needed. There are many drawbacks for the
AMF panel that is used nowadays. The generator and AMF panel is
usually kept at a distance from the control room due to safety factors. It
is a main disadvantage that the present day AMF panel can’t be
controlled from the control room. Since in the proposed system, a
remote relay unit which works as same as Wi-Fi module is added, the
panel can be controlled from a distance. Moreover, the fuel level in the
Generator can also be seen from a distance. The fuel level is sensed by a
sensor which is one of the features incorporated in a relay, which is
cheap, easily available and there are no risks for the occurrence of sparks
unlike the resistive sensor used now.

The power supply systems are subjected to frequent faults, which can be
identified using the designed AMF panel. An alarm sound will be
produced in the case of occurrence of a fault or if the utility supply fails
and the load will be disconnected from the power supply in order to
Protect the load from damage and to provide continuous supply.

Hardware modeling will be helpful in order to validate the results


completely before adopting the newly introduced system into action.
The proposed idea solves the disadvantages of the present system and
moreover it is an innovative concept in the field of energy conservation.
The proposed system is unavoidable in the present era having crucial
energy crisis.

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7.3 BIBILOGRAPHY:
 // WWW.IJESRT.COM

 A textbook on “Switchgear and protection”, by J.B


Gupta.

 Google

 https://www.google.co.in/#newwindow=1&q=amf+panel+
working

 Wikipedia

 https://www.google.co.in/#newwindow=1&q=amf+panel+
with+ats

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