LOW VOLTAGE CONTROL AND SYSTEMS LAB SETUP

I. Low Voltage Electrical Installation Panel Setup

Structure

• Cabinet Type: Wooden cubicle with MS frame
• Dimensions: Height: 1.2 m × Width: 1.2 m × Depth: 0.9 m
• Quantity: 05 units

Each panel is equipped with standard low voltage components to simulate electrical wiring, circuit protection, switching, and control scenarios typically found in residential, commercial, or industrial installations.

Component List (Per Setup)

• Distribution Board (DB) – 3 Tier, 36 Modules: 10 Nos
• RCCB – 2 Pole, 40A, 30mA, AC-type: 10 Nos
• MCB (Miniature Circuit Breakers):
  • 1P, 6A, C Curve, 10 kA: 20 Nos
  • 1P, 10A, C Curve, 10 kA: 10 Nos
  • 1P, 16A, C Curve, 10 kA: 10 Nos
  • 1P, 25A, C Curve, 10 kA: 10 Nos
• Contactors – 40A, 3NO, 220–240V AC: 10 Nos
• Impulse Relay (ITL) – 16A, 2NO, 230/240V AC, 50–60Hz: 10 Nos
• Time Switches – 24H mechanical, no power reserve: 5 Nos
• Electronic Timer – Adjustable (30 seconds to 20 minutes): 5 Nos
• Sensors:
  • Wall Mount Sensors: 5 Nos
  • Ceiling Mount 360° Occupancy Sensors: 5 Nos
• Switches:
  • 6A Bellpush Switch, 2 Module: 10 Nos
  • 6A 1-Way Switch: 10 Nos
  • 6A 2-Way Switch: 10 Nos
  • 20A DP Switch with Indicator: 40 Nos
• Sockets & Fan Control:
  • 6A Universal Socket with Shutter: 80 Nos
  • 6A/16A 3-Pin Socket Outlet: 80 Nos
  • Electronic Step Fan Regulator: 80 Nos
• Faceplates & Grids:
  • 3M Universal Grid & Cover Frame: 20 Nos
  • 4M Grid & Cover Frame: 20 Nos
  • 8M Grid & Cover Frame: 10 Nos
  • Blank Off Cover: 60 Nos

II. Study Case – Grounding Scheme and Selectivity (TT System)

This study setup is used to simulate TT-type earthing system with fault scenarios and protection components to ensure safety and selectivity analysis.

Key Learning Outcomes:

• Effects of grounding
• Earth fault protection and device tripping coordination
• Understanding Vigirex differential protection

Components Included:

• Isolating Transformer – 1 No
• Set of Resistors (to simulate human/equipment load) – 1 Set
• Vigirex Differential Relay – 1 No
• Circuit Breaker with Voltage Emission Tripping Device – 1 No
• Circuit Breaker with 300 mA Differential Protection – 1 No
• Circuit Breaker with 30 mA Differential Protection – 1 No
• Fault Simulation Push Button – 1 No
• General Protection Circuit Breaker – 1 No
• Power Supply Cable – 1 No

III. Study Box – Compensation of Reactive Energy

This unit is designed to teach power factor correction through controlled capacitive compensation.

Core Learning Areas:

• Power factor analysis
• Behavior of inductive and capacitive loads
• Real vs reactive power measurement

Components Included:

• Halogen Lamps on Dimmer – 3 Nos
• Phase Offset Induction Coil – 1 No
• Capacitors for Compensation – 8 Nos
• Control Switches:
  • For Capacitors – 8 Nos
  • For Lamps – 3 Nos
  • For Induction Coil – 1 No
  • For Dimmer Shunt – 1 No
• Light Dimmer – 1 No
• Measurement Points:
  • For Current Consumption – 1 No
  • For Network Voltage – 1 No

• Power Lead – 1 No

IV. Engineering Software (With Educational Licensing)

A powerful engineering suite supporting electrical, fluid, and pre-planning design.

Specifications:

• License Validity: 3 Years
• Subscription: 1 Faculty + 50 Students
• Disciplines Covered:
  1. Electrical Design for Machines & Plants
  2. Fluid Engineering
  3. Pre-Planning
  4. Pro Panel Module
  5. Building Installation & Distribution Diagrams
  6. Auto Diagram Generator
• Features:

• Unlimited pages
• ERP/PDM bidirectional interfaces
• Neutral format export
• Mechatronic process support

• Documentation: Hard copy + Soft copy with examples, exercises, conformity certificates, and global certification for trainees

V. Tools & Consumables

General Hand Tools:

• Cordless Drill 12V – 5 Nos
• Spirit Level (1 ft) – 5 Nos
• Steel Rule (1 mtr) – 5 Nos
• Wire Stripper – 5 Nos
• Side Cutting Plier – 5 Nos
• Combination Plier – 5 Nos
• Heavy Duty Cable Cutter – 1 No
• Center Punch – 1 No
• Try Square – 5 Nos
• Measuring Tape – 5 Nos
• Hack Saw Frame & Blade – 5 Each
• Mini Hacksaw – 5 Nos
• Ball Peen Hammer – 3 Nos
• Crimping Tool (Ring Type) – 3 Nos
• Crimping Tool (Pin Type) – 3 Nos
• File Set – 1 Set
• Adjustable Wrench – 2 Nos
• Pipe Wrench – 1 No
• Electrician Knife – 5 Nos
• Allen Key Set – 2 Nos
• Hole Saw 22mm – 5 Nos
• Heat Gun – 1 No
• Screwdriver Set – 10 Sets
• Bolt Cutter – 1 No
• Ratchet Spanner Set – 3 Sets
• Threading Tool Set – 1 No
• Nose Plier – 5 Nos
• Drill Bit Set – 5 Sets
• Mini Screwdriver Set – 10 Sets
• GI Pipe Bending Tool – 1 No
• Aluminium Staircase (3-step) – 5 Nos
• PVC Pipe Bending Spring – 5 Nos
• Spanner Set – 5 Sets
• Soldering Gun with Accessories – 3 Sets

Installation Accessories:

• Perforated Cable Tray (100×24 mm) – 25 m
• PVC Casing-Capping:
  • 100×50 mm – 25 m
  • 50 mm – 25 m
  • 25 mm – 25 m
• PVC Conduit, 19 mm HD – 37 m
• GI Conduit, 19 mm – 7 m
• Saddles, 19 mm – 500 Nos
• PVC Junction Boxes (1, 2, 3, 4 way – 19 mm) – 50 Each
• Ceiling Plates – 50 Nos
• Batten Holders – 50 Nos
• Cable Ties 150mm – 5 Pkts
• Connector Dominoes (4 mm²) – 500 Nos
• PVC Surface Boxes:
  • 1-Module – 25 Nos
  • 3-Module – 120 Nos
  • 4-Module – 20 Nos
  • 8-Module – 20 Nos
• Wooden Screws (¾″) – 1250 Nos
• Self-Drilling Screws – 250 Nos

Wiring Cables:

• 1.5 sq.mm: Red, Yellow-Green – 8 Coils Each
• 2.5 sq.mm: Red – 3, Black – 3, Yellow-Green – 1
• 4 sq.mm: Red – 2, Black – 2, Yellow-Green – 1

VI. Safety Equipment & Electrical Measuring Instruments

PPE & Safety Tools:

• PVC Insulated Gloves – 10 Nos
• Helmets – 5 Nos
• Insulated Tool Kits – 5 Sets
• Security Padlock + Labels – 1 Set
• Safety Chain with 4 Poles – 1 Set
• Safety Harness – 1 No
• Safety Goggles – 10 Nos

Measurement Equipment:

• Digital Multimeter (CAT III, 600 V, Class 2) – 3 Nos
• Current Clamp Meters – 2 Nos
• Earth Tester (with leads and spikes) – 2 Nos
• Megger (500 V) – 2 Nos