Electrical Installation, Maintenance and Testing Electrical engineering

EXPERIMENT NO. 5

AIM: - Construction, working and troubleshooting of any two household Electrical

equipment's like ceiling fan & mixer grinder.

INTRODUCTION:
In this experiment, we will explore the construction, working principles, and troubleshooting
techniques of two common household electrical equipment: the ceiling fan and the mixer.
Understanding the inner workings of these appliances will help us grasp the fundamentals of
electrical equipment and enhance our troubleshooting skills.

SAFETY PRECAUTIONS:
Before conducting any experiments, ensure you adhere to the following safety precautions:
• Wear appropriate safety gear, including goggles and gloves.
• Do not touch any electrical components with wet hands.
• Disconnect the equipment from the power source before handling or inspecting it.
• Follow all local safety regulations and guidelines.

REQUIRED MATERIAL LIST:

To conduct the experiments, you will need the following equipment:
▪ Ceiling fan
▪ Mixer grinder
▪ Multimeter
▪ Screwdrivers (Phillips and flathead)
▪ Wire cutters
▪ Wire strippers
▪ Electrical tape
▪ Safety gloves
▪ Safety goggles

EQUIPMENT 1 – MIXER GRINDER

a. Construction:

The mixer grinder has following parts which plays major role in running the machine: -
Universal Series Motor
Universal series motors are those which are designed to operate with both AC and DC supply.
Here the word 'series' used because its field windings are connected in series with the
armature winding.
In the circuit diagram, you can also see there are two series windings. One of these is tapped
in three positions. And those tapings are connected to the speed control switch. So, this
arrangement is for speed control of the motor. So, we can obtain three different speeds (low,
medium, high) by rotating the switch. Also, you can see the mixer grinder motor connection
below.

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Thermal Overload Relay or overload switch

A thermal Overload Relay or overload switch is used to protect the device from overload or
overcurrent fault. If the motor draws overcurrent due to any internal fault, or improper use,
the overload relay will automatically disconnect the power supply to the motor. As the mixer
grinder is a home appliance, so the thermal overload relay is very helpful to prevent accidents
such as burning of motor, fire, and melting due to over current. The overload switch also
helps to turn off the motor if you run it for a long time. After fully cool down it will be got
automatically turned on. You can see the mixer grinder overload switch connection diagram.

Three-Position Rotary Switch

It has a total of four terminals. The first one is the input terminal and the other three are
output terminals where the terminals of the motor are to be connected. You can see the mixer
grinder rotary switch connection diagram below.

Power Switch
Most of the mixer grinders have the function to switch on and off in their speed control switch
but some mixer grinders come with a separate power switch to on and off.

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b. Working Principle:

1. Whenever a current-carrying coil is placed in a magnetic field it experiences a force,

which produces a torque that can rotate the coil. The direction of force is determined by
the Fleming left-hand rule.
2. A motor is a machine that converts electrical energy into mechanical energy. Universal
motor is a special type of motor which can work for both A.C (single-phase) and D.C
current.

A universal motor

3. When the current passes through the field winding it produces an electromagnetic field, hence
acts as an electromagnet. The rotor starts rotating as it acts as a current-carrying coil present
in a magnetic field. The same current which passes through the field winding also flows
through the rotor winding that’s why whenever AC current changes direction, the direction of
current changes in both field winding and armature, and hence the movement of the rotor is
not affected.

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Working of universal motor

The main components of a mixer grinder are universal motor which consists of: rotor, carbon
brushes, commutator, and field winding, rotary switch to alter the speed, indication lamp, and a
plug. Whenever we switch on the mixer grinder, universal motor comes into action as current
passes through both the field winding and armature winding and as a result, a torque is applied
on the rotor, the rotor starts rotating which then rotates the blades of the grinder and thus it
helps in mixing and grinding of the ingredients.

c. Troubleshooting Guide:
1. Mixer grinder not starting or not functioning:
• Cause: Power supply issue, such as a loose power cord or a tripped circuit
breaker.
• Troubleshooting: Check the power cord connections, ensure it is properly
plugged in and the socket is functioning. Reset any tripped breakers or replace
blown fuses.
2. Motor not running or making unusual noises:
• Cause: Overloading the motor, worn-out motor bearings, or damaged motor
windings.
• Troubleshooting: Make sure you're not overloading the mixer grinder with
excessive ingredients. If the noise persists, contact a technician to inspect and
potentially replace the motor.
3. Blades not spinning or rotating slowly:
• Cause: Jammed blades due to excessive ingredients or foreign objects, worn-
out or damaged drive couplings.
• Troubleshooting: Turn off and unplug the mixer grinder. Clear any obstructions
or foreign objects from the blades carefully. If the drive couplings are damaged,
they may need replacement.
4. Excessive vibration during operation:
• Cause: Unevenly distributed ingredients, damaged or unbalanced blades.
• Troubleshooting: Ensure the ingredients are evenly distributed in the jar. If the
vibration persists, the blades might be damaged or unbalanced, requiring repair
or replacement.
5. Overheating and automatic shut-off:
• Cause: Continuous operation for an extended period, motor overload, or
ventilation blockage.
• Troubleshooting: Allow the mixer grinder to cool down, then check for any
blockages in the ventilation area. Avoid overloading the appliance and give it
breaks during extended use.

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6. Electrical sparks or burning smell:

• Cause: Faulty wiring, damaged motor, or worn-out electrical components.
• Troubleshooting: Immediately switch off and unplug the mixer grinder. Contact
a qualified technician to inspect and repair the electrical components or motor.

d. Experiment Procedure:
▪ Set up the necessary equipment and ensure safety precautions are followed.
▪ Choose a common issue (e.g., mixer not starting) and discuss potential causes.
▪ Use the multimeter to measure voltage and continuity at various points in the circuit.
▪ Inspect the motor brushes, power cord, and switches for any signs of damage.
▪ Apply appropriate troubleshooting techniques to identify the root cause and propose a
solution.
▪ Document your observations and findings.

EQUIPMENT 2 – CEILING FAN

a. Construction:

1. Electric motor:
Single phase capacitor run and start induction motor, rated at 230 V ± 10 % at a frequency of
50 Hz, is generally employed in ceiling fan. This motor comprises two parts that are stator and
rotor. The stator, build-up of laminated silicon steel, uses two windings termed as starting and
running windings located 90 degrees electrical apart. The starting torque relies on sine of
angle among starting winding and running winding current. Thus, Capacitor is used generate
needed phase shift among these current and therefore to generate high starting torque and

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will be connected in series with starting winding. Generally, in ceiling fan, an electrolytic
capacitor of 2.5 mF±5% will be employed. The capacitor and starting winding will be in circuit
throughout running as well and therefore enhance the power factor. Thus, this motor will also
termed as permanent capacitor induction motor. Rotor uses 1-phase squirrel cage winding.

2. Blades:
The blades are built up of sheet steel or aluminium sheets. Aluminium blades are much lighter
than steel sheet plates and enhance the efficiency of the fan. The ceiling fans generally
comprise 3 or 4 angular blades. The four-blade fan provides more air circulation compared to
three blade fans. The blades are 120o mechanically apart and might be curved at an angle of
10o.

3. Blade flanges:
Blade flanges alternatively termed as blade irons, blade arms or blade holders. These are metal
arms that connect the blades to the motor.

4. Canopy/Switch Cup:
There are two canopies top and bottom, built up of metal cylinder, located along suspension
rod. Top canopy is mounted like that it covers the hook, nut, and bolt. Bottom canopy is
mounted under and in the centre of the motor of the fan. This is employed to conceal and
protect several components that can involve wires, capacitors and switches. On fans which
need oiling, the bottom canopy frequently conceals the oil reservoir that lubricates the
bearings.

5. Ball bearing:
Friction free and noise free movements of rotating parts are made sure through providing ball
bearing among the rotating and stationary parts. The ceiling fan might comprise single or
double ball bearings. The bearings made up of high-quality steel are frequently greased with
superior quality for the long life and noise free operation of it.

6. Suspension rod/Down rod:

Suspension rod is made up of rigid galvanized steel pipe of suitable length and diameter. This
metal pipe is employed to defer the fan from the ceiling. One end of the pipe is bolted or
screwed at the position particularly made on the motor body to receive the suspension rod.
Another end of the suspension rod is attached to 2 plates, to from a "U" shaped joint, along
with the help of a nut and bolt (with extra lock nut).
The "V" shaped end of the rod is additional attached with the ceiling hook along with the help
of bolt and nut with extra lock nut and split pin to eliminate chances of disconnection at some
stage.

7. Speed regulator:
Speed regulator is employed to control the speed of the fan. The speed of the fan can be
changed by altering the applied voltage. The most general technique to change the applied
voltage is
i) By tapped field resistors and
ii) By tapped series inductors.
These days thyristor based electronic type regulators mainly employed compared to above
mentioned electric types.

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Diagram - Resistance type Fan regulator

The regulator of electronic fan is fault-free, have a long life and more efficient as compared to
electrical fan regulators. The schematic diagram of a fan with resistance type regulator is
displayed in the above diagram.

b. Working Principle:
The ceiling fan has a motor that converts electrical energy into mechanical energy. First, the
capacitor of the ceiling fan torques up the electric motor, thereby causing it to start and run.
As the electrical current reaches the motor, it enters coils of wire that are wrapped around a
metal base. When this current passes through the wire, it creates a magnetic field which
further exerts force in a clockwise motion. In this way, the electric energy is converted into
mechanical energy and causes the motor coils to spin. The blades attached to the motor also
start gaining motion with the spinning of the coils.

How The Ceiling Fan Cools - The mechanism behind the ceiling fan is quite simple. It is a
known fact that air naturally stratifies - the lighter, warm air rises while the cool air, that is
heavy, sinks down. The rotation mechanism of the ceiling fan is built in way to attract the
warm air upwards. As the hot air rises, the blades of the fan slice this air and push it down. This
being a continuous process causes the air in the room to circulate in the entire room. Thus, a
ceiling fan only moves the air around. Contrary to the common belief, fans do not exactly cool.
Rather they speed up the process of evaporation of sweat on our body, which naturally makes
us feel ‘cool.’

c. Troubleshooting Guide:
1. Ceiling fan not working at all:
• Cause: Power supply issue, such as a tripped circuit breaker, a blown fuse, or a
disconnected power source.

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• Troubleshooting: Check the circuit breaker or fuse box to ensure power is

reaching the fan. Reset any tripped breakers or replace blown fuses. Verify that
the fan is properly connected to a power source, and check the wiring
connections.
2. Fan not running at the desired speed:
• Cause: Faulty fan switch, improper wiring, or damaged speed control
mechanism.
• Troubleshooting: Ensure that the fan switch is properly connected and
functioning. Check the wiring connections between the switch and the fan
motor. If the speed control mechanism is damaged, it may need replacement.
3. Lights on the fan not working:
• Cause: Burnt-out bulbs, faulty light switch, or wiring issues.
• Troubleshooting: Replace any burnt-out bulbs with new ones of the correct
wattage and type. Test the light switch and ensure it is properly connected.
Check the wiring connections between the lights and the power source.
4. Fan or lights operating intermittently:
• Cause: Loose wiring connections, faulty connections, or a defective fan motor.
• Troubleshooting: Inspect all wiring connections and tighten any loose or
disconnected wires. Check for any damaged or frayed wires that may need
repair. If the problem persists, the fan motor may be defective and require
professional repair or replacement.
5. Fan making unusual noises or vibrations:
• Cause: Loose screws, loose blades, motor issues, or imbalance.
• Troubleshooting: Check and tighten all screws and bolts in the fan assembly.
Ensure that the blades are securely attached and not warped. Balance the fan
blades using a balancing kit or by interchanging the positions of the blades. If
the noise or vibration continues, the motor may be faulty and require repair or
replacement.
6. Remote control not operating the fan:
• Cause: Dead batteries in the remote, signal interference, or a faulty receiver.
• Troubleshooting: Replace the batteries in the remote control with new ones.
Ensure that there are no obstructions between the remote and the fan receiver.
If the problem persists, the receiver may be defective and require repair or
replacement.

d. Experiment Procedure:
▪ Set up the necessary equipment and ensure safety precautions are followed.
▪ Choose a common issue (e.g., slow speed) and discuss potential causes.
▪ Use the Multimeter to measure voltage and continuity at various points in the circuit.
▪ Inspect the wiring connections, capacitor, and motor for any signs of damage or
wear.
▪ Apply appropriate troubleshooting techniques to identify the root cause and propose
a solution.
▪ Document your observations and findings.

CONCLUSION:

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