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ELECTRICAL MACHINES ANDAPPLIANCESTheoryVOCATIONAL EDUCATIONHigher Secondary - Second YearA Publication underGovernment of TamilnaduDistribution of Free Textbook Programme(NOT FOR SALE)Untouchability is a SinUntouchability is a CrimeUntouchability is InhumanTAMIL NADUTEXTBOOK CORPORATIONCollege Road, Chennai - 600 006.Government of TamilnaduFirst Edition – 2011CHAIRPERSONDr. J. KANAKARAJASSOCIATE PROFESSORDEPT. OF ELECTRICAL & ELECTRONICS ENGINEERINGPSG COLLEGE OF TECHNOLOGYCOIMBATORE – 641 004AUTHORSMs. A. Sumathi Mr.R. KrishnakumarAssociate Professor Assistant Professor(Senior Grade)Dept. of Electrical & Electronics Engg. Dept. of Electrical & Electronics Engg.PSG College of Technology PSG College of TechnologyCoimbatore – 641 004 Coimbatore – 641 004Mr P. Balasubramanian Mr.K.S. Sampath NagarajanVocational Instructor (Spl. Grade) Vocational Instructor (Spl. Grade)Municipal Boys Hr.Sec School Govt. Hr.Sec SchoolPollachi - 642 001 Parava kottai - 614 015Coimbatore District. Thiruvarur District.This book has been prepared by the Directorate of School Education on behalf of theGovernment of TamilnaduThis book has been printed on 60 G.S.M. PaperPrinted by Offset of:iiHIGHER SECONDARY – VOCATIONAL COURSEELECTRICAL MACHINES AND APPLIANCESSECOND YEAR – THEORY SYLLABUS1. Winding Insulating MaterialsIntroduction – Electrical properties – Classification – Characteristics – Application areas insulationmaterials – plastics – insulating varnishes - Types of Insulating varnishes2. Winding WireIntroduction – Properties – Characteristics – Choice of Conductor material – Enamelled wire –Grades – Properties – Types & shapes of winding wires – Gauge plate3. Details of windingCoil details – shapes of slot – slot insulation – coil formation – Stator (stationary) winding –Rotor (rotating) winding – DC Armature winding - Lap winding – wave winding – whole coilwinding – half coil winding – concentrated winding – distributed winding - single layer winding –double layer winding – single phase winding – three phase winding – concentric winding –chain winding.4. Development of winding – AC machinesSingle phase windings – Lap winding – wave winding – concentric winding – Three phasewinding – single layer winding – double layer winding.5. Development of winding – DC machinesGeneral procedure – Double Layer simplex Lap winding – Double layer duplex Lap winding –Double Layer simplex wave winding.6. Rewinding and Testing of Electric MotorsMethods of Rewinding – Testing the new winding – Testing of Armature – Insulation resistancetest - Growler test - Drop test.7. Instruments and TestingIntroduction – Voltage tester screwdriver – Continuing Test – Insulation test – Measurement ofPower for DC & AC Circuits.8. Electrical Cooking AppliancesIntroduction – Types – Construction – Electric Toaster – Types – Automatic and Non-Automatic.9. Electric Iron BoxTypes – Non-Automatic – Automatic – Construction and Working – Comparision – TroubleShooting – Steam Iron Box.iii10. Water Heaters & Coffee makersWater Heater – Function – Types – Electric Kettle – Immersion water heater – Constructionand working – storage water heaters – Non pressure type – pressure type – construction andworking – repairs & remedies – Coffee maker – types – construction and working of percolatortype.11. Electric Mixer & Egg beatersElectric Maker – Function – Construction – General Operating Instruction – Caution – Cleaning– Repairs and Remedies – Egg beaters – Hand operated crank type – Electric type – Construction.12. Vacuum Cleaner and washing machineVacuum Cleaner – Function – Principle – Main components – features – types - working –accessories - Filters – Repairing.Washing Machine – Function – Types – Semi and Fully Automatic – Top and Front loading –washing technique – working cycle – construction and working of washing machine – comparisonof Top and front loading machines – Problems and Remedies.13. Electric Fan & Hair DrierElectric Fan – Function – Terminology – Construction and Working of Ceiling & table fans –Exhaust Fan – General Fault and Remedy.Hair Drier – Function – Types – Construction and working – safety features – repairs & remedies.14. Centrifugal Pump :Introduction – Constructional features – working – friction lead – static suction head – staticdelivery lead –automatic operation of pump – Trouble shooting.15. Maintenance of Rotating MachinesIntroduction – Types of maintenance – preventive maintenance schedule – Fitting and removingof a bearing - Maintenance of bearing – Balancing – Preventive maintenance of electricequipments – General procedure for overhaul of motors – Maintenance of AC Motors ––Insulation resistance of a motor - Defects in brushes, brush gear - Trouble shooting chart –defects in commutator – Degreasing – Varnish application - Vacuum Impregnation.16. Maintenance of Transformers :Introduction – Action taken for rise in oil temperatures and falling of oil level – methods of dryingout of transformers – Time of drying out operation - Qualities for Transformer oil – methods ofpurifying and drying out of transformer oil – Checking of dielectric strength of transformer oil –action taken for transformer failure - periodical overhaul.ivCONTENTS1. Winding Insulating Materials 12. Winding wire 153. Details of winding 244. Development of Winding - AC machines 365. Development of Winding - DC machines 646. Rewinding and Testing of Electric motors 757. Instruments and Testing 898. Electrical Cooking Appliances 979. Electric Iron Box 10210. Water Heaters and Coffee Makers 10911. Electric mixer and Egg Beaters 11812. Vacuum cleaner and Washing machines 12413. Electric Fan and Electric hair drier 13814. Centrifugal Pump 15215. Maintenance of Roatating machines 16016. Maintenance of Transformers 179Page No.v11. WINDING INSULATING MATERIALS1.1 INTRODUCTIONThe Electrical insulating materials are defined as materials which offer a very large resistanceto flow of current, and for that reason they are used to keep the current in its proper path alongthe conductor. This is evident when we touch an electric machine when it is under operation.We don’t receive any electric shocks, because of the insulation. Breakdown of insulation resultsin short circuiting of the coils, causing electric currents to flow in unintended paths. This mayalso cause, electric shocks to humans operating the machinery and also damage the machines.Requirements of a good insulating materials involve physical properties, reliability, cost,availability, adaptability to machining operations etc. Electrical insulation and dielectric materialsincludes various forms of materials that surround and protect electrical conductors and preventunwanted current flow, leakage. Electrical specifications include electrical resistivity, dielectricstrength, and dielectric constant.
1.2 ELECTRICAL PROPERTIES
Electrical Resistivity : It is the electrical resistance (ohm-cm) to the flow of current through it.
Its value should be very high. Resistivity is the inverse of conductivity.
Dielectric Strength : Dielectric strength is the maximum voltage gradient that the material can
withstand before electrical breakdown occurs. This value specified as ‘kV/mm’ should be very
high even for very thin films.
1.3 CLASSIFICATION OF INSULATING MATERIALS : The insulating materials are classified
in the following two ways : 1. Classification according to substances and materials.
2. Classification according to temperature.
Classification according to substances and materials :
(i) Solid Insulating Materials [Inorganic and organic]
Mica, wood, slate, glass, porcelain, rubber, cotton, silk, rayon, terylene, paper and
cellulose materials etc.
(ii) Liquid Insulating Materials [Oils and Varnishes]
Refined hydrocarbon minerals oils, Linseed oil, spirit and synthetic varnishes, etc.
(iii) Gaseous Insulating Materials
Dry air, carbon dioxide, argon, nitrogen, etc.
Classification according to temperature : The insulating materials are classified mainly based
on the thermal limit. The performance of the insulation depends on its operating temperature.
The higher the temperature, the higher will be the rate of its chemical degrading, and hence the
lower will be its useful life as shown in fig.1.1. If a reasonably long life of insulation is expected,
its operating temperature must be maintained low. Therefore, it is necessary to determine the
limits of temperature for the insulation, which will ensure safe operation over its expected life.
2
Thus the insulating materials are grouped into different classes Y, A, B, and C with
temperature limits of 900 C, 1050
C and 1300C for the first three classes and no specific limit
fixed for class C. Class Y and A cover the various organic materials without and with impregnation
respectively, while classes B and C cover inorganic materials, respectively with and without a
binder. With the existence of newer insulating materials, namely, the plastics and silicones,
during the middle of this century, a need was felt to reorganize the classification of the insulating
materials. This calssification is shown in fig.1.2. This led IEC (International Electro technical
Commission) to come up with the new categories:
Class Y : 900
C: Paper, cotton, silk, natural rubber, polyvinyl chloride, etc. without impregnation.
(formerly O)
Class A : 1050
C: Same as class Y but impregnated, plus nylon.
Class E : 1200
C: Polyethylene terephthalate (terylene fibre, melinex film), cellulose triacetate,
polyvinyl acetate enamel.
Class B : 1300
C: Mica, fiberglass (alkali free alumino borosilicate), bituminized asbestos,
bakelite, polyester enamel.
Class F : 1550 C: As class B but with alkyd and epoxy based resins, polyurethane.
Class H : 1800
C: As clas
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