UNIT 4.

7 POWER FEED SYSTEMS

Contents

1. Alternating and Direct Current

2. Electricity supply

3. Earthing

3.1 Earthing explained

3.2 Portable equipment

4. Current supply systems

4.1 Power feed systems

4.1.1. Bare copper wires

4.1.2 Coiled cable

4.1.3 Cable reeling drum

4.2 Festoon cable systems

4.2.1 Taut wire

4.2.2 Trailed cable systems

4.3 Control

4.4 Cable selection

4.5 Shrouded conductor systems

4.6 Totally enclosed conductor systems

4.7 Connecting the power supply to the conductor system

4.7.1 Festoon cable

4.7.2 Shrouded conduction systems

4.8 Examination of power feed systems

4.8.1 Bare copper wires

© Lifting Equipment Engineers Association 2013 - training\4-7u Rev 1.1 2013 1

 4.8.2 Coiled cable

4.8.3 Cable reeling drum

4.8.4 Festoon systems

4.8.5 Shrouded conductor systems

4.9 Insulation and continuity testing

© Lifting Equipment Engineers Association 2013 - training\4-7u Rev 1.1 2013 2

Introduction

In this unit we will initially consider basic electrical theory. Studies will be confined to
those matters which ultimately affect our dealings with lifting equipment and therefore will
be far from a study of the full subject. It should also be noted that the unit is written in a
simplistic form which is intended to establish only some basic principles. The aim is to
give those with little or no knowledge of the subject sufficient foundational understanding
of the topic and to provide the basis for further study in the future.

This unit will then begin to consider electrical machines, starting with the main types of
power feed systems used with electric power operated lifting appliances. It will address
the important characteristics of each system, advantages and disadvantages, and their
examination. As there are several variations of each system, each manufacturer having
their own, these considerations are of a general nature. The student is therefore advised
to note as many types as possible and refer to the manufacturer’s installation
instructions.

1. Alternating and Direct Current

Conductors which are used to supply factories are made from materials which provide an
easy path for the flow of electric current, e.g. copper and aluminium.

Whenever a current flows in a conductor, a magnetic field is created around it and this
effect can be increased by forming the conductor into a coil. The strength of the magnetic
field is proportional to the strength of the current and the number of turns in the coil. This
effect is reversible so that if a magnetic field is applied to a conductor, say in the form of
a coil, a voltage will be induced in the coil.

The interaction between electricity and magnetism is the principle by which motors,
generators, transformers and relays work. It is also the principle by which electricity is
generated.

In a modern electricity generator or alternator, the part that revolves is called the ‘rotor’

© Lifting Equipment Engineers Association 2013 - training\4-7u Rev 1.1 2013 3

and comprises the electro-magnets. The stationary part is called the ‘stator’ and is made
up of conductors. As the rotor revolves, its magnetic field cuts across the stator
conductors and causes a current to flow in them. The rotor can be considered as a
magnet revolving within the stator. Now as it revolves, so the strength and direction of
the magnetic field will vary. This means that the voltage and current induced in the stator
conductors will vary. Figure 1 shows the way the voltage and current vary in just one
revolution of the rotor. This is called a ‘sine wave' and hence the current is called
alternating current (AC) since it changes from a maximum in one direction to a
maximum in the opposite direction in each cycle.

+ Voltage

- Voltage

1 Cycle

Figure 1
An alternating current cycle

Generators used to supply electricity in the UK have rotors which complete one cycle in
1/50th of a second, thus producing electricity which alternates at 50 cycles per second or
50 hertz (Hz). This is known as the frequency of the supply.

If an external conductor is connected to the stator while the rotor is revolving, the induced
voltage will cause a current to flow in the conductor and back to the alternator. This is a
simple single phase system. However, if the alternator conductors are spaced in three
groups 120° apart, then the induced voltage in each will be a minimum and maximum at
different times during the cycle. This system is known as a three-phase system and is
the standard used in the UK.
A three-phase AC system consists of three conductors with a common neutral (return)
conductor at earth potential. In a three-phase system the voltage between any pair of
phases is 1.74 times the voltage to earth. In the UK system the voltage between any
phase and earth is now 230V and the voltage between any two phases is 1.74 x 230 =
400V

© Lifting Equipment Engineers Association 2013 - training\4-7u Rev 1.1 2013 4

An AC system is called single-phase if the circuit consists of one phase, i.e. the live
conductor, and a neutral conductor in addition to any earth conductors.

If a conductor is connected to the two terminals of a battery, then a current will flow in the
conductor from one terminal to the other. This current will be at a single value dependant
on the energy of the battery and it will only flow in a single direction. This is known as
direct current (DC).

Direct current can be produced by a generator in which the AC is rectified to a

single-directional flow using a commutator connection to the generator. Direct current is
now little used in transmission and distribution systems which supply electricity, although
some special applications still apply. However, at one time it was common in industry.

2. Electricity supply

With electricity, the size of the conductors have to be larger when carrying higher current.
A further principle is that if the voltage is increased, the current is decreased. This is the
main reason why power transmission lines have such high voltages.
With the aforementioned in mind, energy from the various power stations is fed into the
national grid system at 400 kV or 275 kV. Area distribution companies take their supplies
from tapping points on this system and have primary distribution at 132 kV. From this
primary the supply is then transformed down to 33 kV, then 11 kV and finally to 400 volts
and 230 volts supplying the low voltage distribution network.

Most factories and offices receive electricity supplies at 400 volts and 230 volts.
However, some large concerns are supplied direct from 33 kV and 11 kV networks - in
which case the company provides its own sub-station for 400/230 V conversion.
Urban electricity supplies are usually fed underground, whilst in rural areas the feed is
commonly by overhead cables.

Figure 2 shows a typical supply network from a local substation to a factory. For this
exercise, we can forget about the higher voltages which are used for transmission only.

© Lifting Equipment Engineers Association 2013 - training\4-7u Rev 1.1 2013 5

 Local Sub Station Three phase switch
Fuses Lamp

Brown phase Motor

Blue Neutral conductor Steel casing

Black Phase

Grey Phase

Earth

Transformed 3 Phase star connected supply

Figure 2
Supply distribution in a factory (3 phase, 4 wire supply)

Function Colour of Core of Colour of Core before

rubber or PVC the changes to meet
insulated cable European standards
Earthing Green and Yellow Green
Live conductor of Single Brown Red
Phase AC circuit
Neutral of Single or Blue Black
Three Phase AC circuit
Phases L1 l2 L3 Brown Black and Grey Red, Yellow and Blue
respectively of Three
Phase AC circuit

The above chart shows the standard colours which are used today as the European
standard.
It will take many years before all systems are marked with the new colours so it is best to
remember what the previous marking was. They are therefore shown in the end table.
Brown and blue have been used in flexible single phase cables for a long time now. The
colours which cause the most confusion are black and blue which can be either neutral
or phase depending on the age of the installation.

© Lifting Equipment Engineers Association 2013 - training\4-7u Rev 1.1 2013 6

Note:
The Electricity Supply (Amendment) (No2) Regulations 1994, which implement an
amendment to the European Directive, require the electricity supplier to declare to the
customer the voltage at which the supply will be made.

The voltage declared to a new customer must be one of the following:

Low Voltage* -
230 volts on two wire single phase circuits
230/400 volt on 4 wire three phase circuits

*Important note relating to ‘Low’ voltage

The term low voltage is used in the Directive and Regulations to describe the voltage
which it has been transformed down from the generated voltage for supply purposes and
is defined as less than 1000 volts. The use of this term in the regulations is unfortunate
as it is the same term used to describe voltages that have been reduced to 110v or less
for safety reasons and care must be taken not to confuse the two very different
meanings.

The United Kingdom has agreed to the timetable set by CENELEC to harmonise Low
Voltage supplies in Europe. From 1st January 2003, the standard will be 230 volts with a
tolerance between +10% and -10%.

3. Earthing

It is a requirement of the Electricity at Work Regulations 1989 that precautions shall be

taken, either by earthing or by other suitable means, to prevent danger arising when any
conductor (not part of the electrical circuit) may reasonably foreseeably become charged.
This refers especially to conductive parts of equipment, such as outer metallic casings,
which can be touched and which although not live, may become live under fault
conditions. This is to prevent electrocution when a person receives a shock to ‘earth'.
Earthing means ‘effectively connecting to the mass of the earth'.

The earth is an enormous conductor and any fault current discharged into it is effectively
absorbed and neutralised.

© Lifting Equipment Engineers Association 2013 - training\4-7u Rev 1.1 2013 7

Connections to earth can be made by driving metal rods, or sinking metal plates, deep
into the earth. The use of metallic water mains, although once common as a means of
earthing, cannot always be relied on as water authorities now use plastic water pipes and
large mains of concrete. Hence pipes which emerge as metal at the consumer's
premises may not be metal throughout their length.

3.1 Earthing explained – what really happens to make it safe?

Please look back at figure 2 which shows a very simplistic three phase supply system.
A basic rule in electricity is that there must be a circuit for current to flow.

Look at Fig 2 and follow the brown phase from the ‘star’ connected substation to the
switch. Imagine the switch is closed. Therefore the current continues through the fuse to
the brown section of the motor. It then flows towards the star point of the motor and will
have to decide which path to then take. This is made easy by the constant changing of
polarity of all phases but for this exercise we can pick either one - so we will choose
black. It therefore flows back towards the substation through the black phase and reuses
its circuit again. This circuit will flow for as long as the switch is closed and there are no
other breaks in the circuit.

The fuses are rated for the highest current the motor will use.

If we imagine one of the conductors inside the motor accidently touches the steel body
and an ‘earth fault’ occurs. The motor steelwork is connected to the main factory earth
conductor. We will say that the brown conductor is the one that is accidently touching the
steelwork. We will follow the brown conductor again from the substation, through the
switch and down towards the star point of the motor. There is no problem up to this point,
but when the current tries to reach the star point it now has an alternative path. Electricity
is very lazy and will always choose the easy path – the one which will have the least
resistance. The brown conductor current must choose between the path through its
remaining windings or the large earth conductor with virtually zero resistance. Choice
made, it elects to go through the earth conductor and flows back to the power station.
One other factor comes into play here, namely the amount of current that is kept down by

© Lifting Equipment Engineers Association 2013 - training\4-7u Rev 1.1 2013 8

the motor’s resistance increases to an enormous value due to the resistance free earth
conductor. This enormous current flows back to the power station and then back along
the brown conductor until it comes to the fuse. This is not large enough to cope with the
extra current and acts as a bottleneck, heats up and melts.
If the metalwork was not earthed and was touched by a person, a nasty shock could
result. We will learn more in the next module when basic calculations involving
resistance, voltage and current are looked at and you will learn why a fuse will not
prevent electrocution

3.2 Portable Equipment

When 230V portable electrical equipment is used the earth connection must always be
kept in good condition. If the earth is broken or becomes damaged a dangerous situation
can arise when a fault within the equipment occurs: the operator will receive an electric
shock. At 230V this may prove fatal. To overcome this danger, low voltage supply is
often used (i.e. at 110V). This is made even safer on transformed supplies by connecting
an earth to the middle point of the secondary transformer, as shown in Figure 3.
Consequently any earth shock to the operator will only be at 55V which is then known as
extra low voltage.

230/110V Transformer

55v
230V 110V
55v

Shock to Earth 55V

Earth

Figure 3
Effect of contact with a low voltage transformed supply

A second method used to overcome the danger of electrocution is to use all insulated
appliances, in which all conductors are insulated and have protective casings in the form
of tough insulating material with gears and shafts made of a similar material.

© Lifting Equipment Engineers Association 2013 - training\4-7u Rev 1.1 2013 9

Another alternative is the double-insulated appliance which has both functional and
protective insulation, the latter being in the form of two layers and, for reasons of
strength, is wholly or in part metal clad. These appliances have the advantage that
exposed metal does not have to be earthed, hence no earth wire is required from the
appliance.

4. Current supply systems

Wiring: Mechanical Protection

The following are some of the most common systems used in running and protecting
conductors:

1. Metal conduit - galvanised or enamel

2. Insulated conduit - rigid or flexible
3. Mineral insulated, metal covered - powder is compressed and is
non-flammable. Used where fire protection is required, e.g. fire alarm
system.
4. PVC insulated cable (an additional sheath of PVC)
5. PVC insulated steel wire armoured

4.1 Power feed systems

Other types of conductor systems may be used to carry the supply to travelling blocks
and cranes. The main factory supply is taken to a point adjacent to the equipment and
terminated with a switch fuse/isolator. The power feed to the actual hoist or crane is then
taken from this in one of several ways.

There are five basic systems of power feed:

1. Bare copper wires Fig. 4a and 4b

2. Coiled cable Fig. 5
3. Cable reeling drum Fig. 6a and 6b

© Lifting Equipment Engineers Association 2013 - training\4-7u Rev 1.1 2013 10

4. Festoon cable Fig. 7
5. Insulated conductors Fig. 10 to 12

4.1.1 Bare copper wires

Although this system is considered unsuitable for new installations nowadays, it was
widely used in the past on all types of installations. Many of these old installations may
still be found in service. The general advice is to review the installation; it may be that the
bare wires present a possible danger to people working in the area, in which case the
advice must be given to change this for a more suitable supply system. On the other
hand it may be considered that the system is safe by virtue of its position, in which case it
may be left in service. The owner has a responsibility under section 7 of the Health and
Safety at Work Act to provide safe systems of work and it is their responsibility to change
this if it is considered necessary.

In this system copper wires are stretched parallel to the beam by means of strainer
screws with insulators. A collector bracket is fitted to the hoist on which are mounted the
collectors. The most common form of collector is the bronze roller, graphite bushed, thus
providing good electrical contact and bearing surfaces. Each collection shaft is insulated
from the collector bracket.

For long runs the wires are supported on porcelain reels, the collectors lifting the wires
off the reels as they pass over them.

Figure 4(a) Figure 4(b)

Insulating washer 3" diameter wheel type collectors

The system is suitable for long runs when there is good headroom and the exposed
cables present no danger to personnel either directly or indirectly.

© Lifting Equipment Engineers Association 2013 - training\4-7u Rev 1.1 2013 11

As bare copper wires are not generally recommended they have been superseded by the
following which are considered to be safer systems:

4.1.2 Coiled cable

In the coiled cable the conductors are contained in a PVC compound insulate which is
coiled in a similar manner to a tension spring. The cable is fixed to a swivelling bracket
on the side plate of the trolley with the supply end fixed at a convenient point adjacent to
the runway. As the hoist is moved along the runway so the cable expands, and when the
hoist is moved back so the cable contracts. This type of cable is suitable where only
short travel distances are required due to the sag in the cable. The normal extension
ratio of such a cable is 3 to 1, with a nominal 3 metres extended length.

Figure 5
Coiled cable feed

4.1.3 Cable reeling drum

The cable reeling drum provides a means of power on control using a flexible cable
wound onto a drum which can be played out and then recovered. At the heavy end of the
range, reeling drums can be very large and equipped with geared motors actuated by
torque sensing for cable recovery. This unit deals only with the more common spring
operated type.

Construction is very simple, comprising a steel drum mounted on to a fixed shaft and
rotating on sealed bearings. The power feed cable is clamped to the drum, the wire ends
being connected back to carbon brush gear which rotates with the drum. The power feed

© Lifting Equipment Engineers Association 2013 - training\4-7u Rev 1.1 2013 12

to the drum passes through the fixed shaft to the slip rings which are fixed.

Figure 6(a)
Diagrammatic arrangement of reeling drum

The return springs in a cable reeling drum are of the clock spring or spiral wound type;
see Fig 6(b).

Figure 6(b)
Spiral wound return spring

Since a spiral wound spring does not provide a constant torque, spring selection is very
important. The cable should not be overloaded by too great a tension or have too much
slack, nor should the appliance run back (a possible hazard with coiled cables and
reeling drums if used in association with light weight push/pull trolleys).

Before a drum can be selected the cable size must be determined, taking into account a
number of factors:

© Lifting Equipment Engineers Association 2013 - training\4-7u Rev 1.1 2013 13

(1) Voltage Drop - Unless it is otherwise stated it is usual to work to IEE Regulations
which state that voltage drop shall not exceed 4% of the rated voltage based on
the normal operating current. (See later reference to voltage drop)
(2) Temperature Correction – Generally, for ambient temperatures above 30ºC the
continuous rated current capacities should be eliminated.
(3) Reeling Configurations - Rated cable capacities should be further de-rated
according to the configuration of the reel to be chosen.
(4) Short Time Rated Motors - In many cases the motors on a lifting appliance may be
short time rated thus allowing cable carrying capacities to be increased.

Note:
Although not expected to design electrical power supply systems, the Tester and
Examiner should be able to understand the fundamental requirements of a system. For
example, to enable the tester and examiner to identify the reason for a performance
deficiency of a hoist under test.

Cable Selection

In practice the cable would be selected based on the criteria discussed against technical
data provided for a particular product. An example of cable selection will be discussed in
the next section (Festoon Cable Systems) since it could apply to both systems.

4.2 Festoon cable systems

4.2.1 Taut Wire

The taut wire system is suitable for light duties over lengths not exceeding 30
metres. It is simple and economical to install. The strainer wire is made taut by
means of straining screws whilst the cable is carried on trolleys or, in its simplest
form, on leather “pig-tail” hangers.

© Lifting Equipment Engineers Association 2013 - training\4-7u Rev 1.1 2013 14

 “pig-tail” hanger

Although generally regarded as suitable for light duty, only the taut wire system is
ideal in dirty and dust laden atmospheres.

Figure 7
Taut wire system

4.2.2 Tracked cable systems

The tracked system is a development of the taut wire system. It can support
greater loads and is suitable for higher speeds. Most systems incorporate an
inverted ‘U' section track, the cable support trolleys running on the two inner
ledges.

The manufacturers of these systems offer a range of profile sections for most
loading conditions from light to heavy duty.

The tracked festoon systems are very safe with perfect insulation. Hence there is
no loss of energy or voltage drop where current has to pass from conductor to
collector.

© Lifting Equipment Engineers Association 2013 - training\4-7u Rev 1.1 2013 15

 A limiting factor of the festoon system could be loss of travel of the hoist unit due
to bunching of the trolleys, especially on long track applications. Also, on long
track installations the size of cables would need to be increased to limit voltage
drop, requiring a heavier track system to support them.

In many cases, a lifting appliance will have two festoon tracks: one to carry power
to the hoist and the other providing a mobile pendant push button box (e.g. on the
bridge of the crane).

When a mobile pendant push button box is fitted the festoon cable will terminate in
the pendant control box. The push button box is suspended from the pendant
control box by means of the pendant cable. See figure 9(a).

Figure 8
Tracked cable system

© Lifting Equipment Engineers Association 2013 - training\4-7u Rev 1.1 2013 16

 Figure 9(a)
Typical mobile push button box assembly

Figure 9(b)
Cross section through a pendant control cable

4.3 Control

With the majority of electric hoists the contactor panel is mounted on the main frame and
therefore travels with the hoist. It is recommended practice that control voltages should
not exceed 115 volts. This is achieved by transforming down from a single phase of the
three phase supply. The low voltage control signals are transmitted via the push button
box and multicore pendant cable to the hoist contactor panel.

The purpose made cables may have as many as 25 separate cores depending on the
number of push buttons (see control circuit section). The pendant cable has two
independent strainer wires built in to support itself and the weight of the push button box.

© Lifting Equipment Engineers Association 2013 - training\4-7u Rev 1.1 2013 17

4.4 Cable selection

When selecting a cable, great care must be taken to ensure adequate amperage
(current) capacity is provided.

The most important thing is to deliver enough current to the motor so it will give its
maximum performance.

There are three main factors to bear in mind:

 The cross sectional area of the conductor. The larger the area, the more current it
will carry.
 The length of the cable run. The longer the run, the more resistance, therefore
current will be lost. This is known as the voltage drop effect.
 The temperature. Resistance increases as temperature rises, therefore current will
be lost.

A typical example is a motor that requires 35 amps for maximum performance.

 A 4mm cross sectional area cable is chosen which has a current rating of 40
amps.
 The current of 40 amps will be consistent until the run reaches 20 metres. The
current will reduce to 35 amps after 35 metres.
 The current of 40 amps will remain constant at a temperature of 30 degrees. At a
temperature of 40 degrees a factor of 0.91 has to be applied which will reduce the
current to 36.4 amps.

In summary, a 4mm cable being asked to supply 35 amps at a distance of 35 metres in a

temperature of 40 degrees will only have the capability to supply 31.85 amps.
This example illustrates why it is very important to calculate before selecting the cable.
The IEE regulations have all the formulas, but power feed system manufacturers will help
with this.

© Lifting Equipment Engineers Association 2013 - training\4-7u Rev 1.1 2013 18

4.5 Shrouded conductor systems

Shrouded conductor systems are of various cross sections. The conductor bar is
sufficiently shrouded with a PVC cover to ensure finger safety yet provide access for a
collector shoe to pick up the current.

Figure 10(a) Figure 10(b)

4 Bar shrouded conductor system Cross section of conductor
with collector shoes and cover

Replaceable sintered graphite

collector shoe

Figure 11(a) Figure 11(b)

The collection assembly is spring loaded to ensure good contact with the conductor bar
and articulated to enable the contact shoe to follow the track without binding.

© Lifting Equipment Engineers Association 2013 - training\4-7u Rev 1.1 2013 19

 Figure 11(c)

Figure 11(d)
Typical shrouded conductor system arrangement

© Lifting Equipment Engineers Association 2013 - training\4-7u Rev 1.1 2013 20

4.6 Totally enclosed conductor systems
A totally enclosed conductor system is used where up to five poles are required in one
housing. It is a rigid and compact system and the principles for power rating the system
apply.

Figure 12a
Totally enclosed conductor system

Figure 12b
Typical application of an enclosed conductor system

© Lifting Equipment Engineers Association 2013 - training\4-7u Rev 1.1 2013 21

General

The merits of shrouded conductor systems are a much greater protection against
accidental contact and a suitability for long runs since intermediate feeders can be
added. These systems are available up to 300 amps. They are however unsuitable for
flame proof or similar applications.

Higher operating temperatures can be achieved by using polycarbonate covers (-40°C to

121°C) or laminated fibre glass (-45°C to 149°C).

Expansion

With any rigid system particular attention must be paid to expansion and expansion
couplings fitted, in accordance with manufacturers’ recommendations, if trouble is to be
avoided.

4.7 Connecting the power supply to the conductor system

4.7.1 Festoon cable

As previously discussed, the full length of cable must be taken into account when
checking the voltage drop.

4.7.2 Shrouded conduction systems

With the shrouded conduction system the power feed need not be connected to one end.
By connecting in the centre rather than to one end voltage drop is halved. By connecting
a power feed to each end the voltage drop is halved again.

© Lifting Equipment Engineers Association 2013 - training\4-7u Rev 1.1 2013 22

 End power feed

Figure 12c
End power feed to enclosed conductors

In-line power feed

Figure 12d
Demag in-line power feed to enclosed conductor

4.8 Examination of power feed systems

4.8.1 Bare copper wires

Assess if the system is safe. If it is, the following checks should be made:
 Check wires for burns due to arcing. Replace if burns exceed 25% of diameter.
 Check collector shoes for burns and, if roller collectors, check for burns, loss of
metal and wear of graphite bearings.
 Most burns are caused by vibrations or defective collector mechanisms.
 Wires must not be greased as this will cause arcing.
 Check insulation resistance.

© Lifting Equipment Engineers Association 2013 - training\4-7u Rev 1.1 2013 23

4.8.2 Coiled cable

 Check PVC cover for cracks in the insulation, especially at terminations. Replace
if cracked or damaged.
 The insulations should be checked both visually and with an insulation and
continuity tester (e.g. Megger). The insulation resistance should not be less than 1
Megohm.

4.8.3 Cable reeling drum

 Check drum for smooth running. If movement is erratic bearings should be

checked. Check slip rings, carbon brushes and pressure springs.
 Check cable tension with drum fully wound.
 Check cable tension with cable fully extended (i.e. the hoist at the opposite end).
 Check spare rotation capacity of drum and for a minimum of two remaining turns
of cable on the drum.
 Check cable for cracks and carry out an insulation check.

4.8.4 Festoon systems

 Check taut wire anchors and runners for free movement.

 If a track system, inspect each joint section is tight and properly closed up.
 Inspect cable for cracking, check for loose trolley clamps and carry out a Megger
test for insulation.

Additionally, in the case of festoon control systems:

 Check pendant control box is running freely, festoon and pendant connections are
secure.
 Check pendant secure to push button box.
 Check operation of buttons including any emergency stop and key switch etc.

© Lifting Equipment Engineers Association 2013 - training\4-7u Rev 1.1 2013 24

4.8.5 Shrouded conductor systems

Check for tightness of joints, signs of burning and that covers are in place. Check shoes
for wear, check spring tension and general operation. Check insulation resistance.

General
All power feeds must terminate at a fused isolator. This should have good access from
the shop floor and be clearly identified. The isolator is considered to be part of the power
feed system and should also be carefully examined for correct operation. When
examining a supply system, hoist or crane, the isolator fuses should be removed for
safety.

4.9 Insulation and continuity testing

An insulation test measures the degree of isolation between separate conducting paths
within a system. A continuity test checks that the energy flow is not impeded within an
electrical circuit.

The tests are normally made by an instrument called an `Insulation and Continuity
Tester’ of which the "Megger" is a typical example. A switch on the instrument will select
either the insulation or continuity range.

The instruments may be either battery or hand powered to produce the required output
voltage.

For each type of test the circuit tested must be ‘dead’.

Switched to ‘insulation test’ the instrument will produce a DC output voltage when either
the crank is turned (hand powered) or the test button pushed (battery powered). The
voltage used depends on the circuits being tested but for installations of 400v or less a
500 volts DC output is used. A motor is normally tested using twice the rated voltage.
Therefore a 400v AC three phase motor would be tested using the 1000v DC output. All
connections to brake rectifiers or any other electronic circuits must be opened.

© Lifting Equipment Engineers Association 2013 - training\4-7u Rev 1.1 2013 25

This high voltage enables the very high resistance values encountered to be measured
reasonably accurately. When testing a hoist, the switch box should be opened and the
fuses removed.
On standard three phase motors, tests should be made between each phase and earth
at the switch box.

The resistance reading must not be less than 0.5M when using a test voltage of 500
volts.

Continuity tests are made by switching the instrument to ‘continuity test' giving an output
of 6v DC. Again this is produced by the hand crank or battery depending on the
instrument model. At this low voltage the resistance must not be more than 0.5 ohms ()

When making continuity tests the fuses must be removed and leads connected to each
pair of phases for three phase systems. To check earth continuity a wandering lead is
often necessary to reach from the motor to the switch box etc.

When faults are detected in either test then further investigation is necessary to locate
the source of the fault. This is achieved by a process of elimination, testing each part of
the circuit separately until the defective area is found.

Conductor

`Test Instrument’

© Lifting Equipment Engineers Association 2013 - training\4-7u Rev 1.1 2013 26

Continuitytest. The instrument uses 6 volts. The maximum reading across the
conductor is 0.5 ohms.

Earth

Insulation test. The instrument uses 500 volts between the conductor and earth. The
minimum reading allowed is 0.5 M ohms.

© Lifting Equipment Engineers Association 2013 - training\4-7u Rev 1.1 2013 27