BC - 102
| ITEM | BC - 102 |
|---|---|
| PANEL NUMBER | 7F - B |
| PANEL. SIDE | PMCC - 1 |
| JB SIDE | JH - 4 |
| TYPE | ACB |
| KW | 160 |
| HP | 215 |
| FUSE RATING | ACB |
| POLE | 4 |
| VOLTAGE | 415 |
| F1. AMP | 260 |
| RPM | 1490 |
| SFU RATING | 800A |
| FRAME | ND315L |
| BEARING DESIGN | 6319C3 |
| FLC | 260 |
Electrical ACB Breaker
ACB (Air Circuit Breaker) is an electrical switching device that provides protection against short circuits and overloads in an electrical system. It is commonly used in industrial and commercial applications to control and distribute electrical power. It is capable of interrupting current flow in the event of an overload or short circuit, preventing potential damage to electrical equipment and ensuring the safety of the electrical system.
Working Principle
ACB operates based on the principle of thermal-magnetic protection. It consists of a trip unit that detects the current passing through the breaker. When the current exceeds the predetermined threshold, the trip unit activates the opening mechanism, disconnecting the circuit.
Features
- Overload Protection: ACB can detect and protect against excessive current flowing through the electrical system, preventing damage to the equipment and wiring.
- Short Circuit Protection: In case of a short circuit, ACB reacts quickly to interrupt the current flow, minimizing the risk of electrical fires and equipment damage.
- Adjustable Trip Settings: ACB offers adjustable trip settings for both overload and short circuit protection, allowing customization based on the specific requirements of the electrical system.
- Remote Control Capability: Some ACBs are equipped with remote control features, enabling operators to monitor and control the breaker remotely.
- High Breaking Capacity: ACB is designed to handle high fault currents and has a high breaking capacity to interrupt the current safely.
Maintenance and Testing
Regular maintenance and testing of ACBs are essential to ensure their proper functioning and reliability. Some common maintenance tasks include cleaning, lubrication, and inspection of contacts, trip units, and mechanical parts. Periodic testing, such as trip testing and insulation resistance testing, should also be performed to verify the breaker's performance.
ACBs play a crucial role in electrical system protection, providing safety and reliability. Proper installation, maintenance, and adherence to safety guidelines are essential for the effective operation of ACBs.
Activity prior to the outage
- Review of ACB Tripping history
- Perform visual inspection.
- Measure Temperature using Non Contact Infrance Thermometer.
- Indentify material required during Maintenance
Operating condition of ACB
- High humidity & high ambient temp.
- Frequent switching operations
- Dusty & dirty atmosphere
- Corrosive atmosphere
- Older equipment
- Frequent fault operations
- Frequent racking operations
Activity during the outage:
- Trip the Circuit Breaker
- Follow "lockout tagout" Process
- Check mechanical and Electrical operation
- Perform Inspections and cleaning
- Breaker
- SIC contacts
- Arc Chute
- Jaw
- Cradle
- Cradle contacts
- Main contacts
- Clean pole assembly and Mechanism
- Apply Balmerol Moly Grease (Black) to moving parts of mechanism
- Apply Lithon (yellow) grease to bearing components,
- Apply Licom grease law contacts
- Replace split pin of main spring (In case of EDO/EF ACB)
- Use new wire circlips, pin for UV, facia, retainer, washer wherever required,
- Maintain the arcing contact gap.
- Check simultaneously closing of all pole with pale slow closing test method.
- Gap between trip and roller (0.2 mm min)
- Perform Release Function test with Secondary injection Kit. (In case of electronic release).
- Test functionalities of accessories if any.
- Check tightness of joint
- Affix Maintenance Sticker on ACB
- Energize switchgear and verify normal operation
- Remove Signs,
- Prepare a report of maintenance and test results.
Content of the Service Kit :
- Self Carbon check list.
- Cloth for cleaning (Chese Cloth)
- Cloth for Cleaning Contact
- Scruber (Sctoch Brite)
- Hand gloves
- Wire Cerclip 4,5,6 Mm
- Lithon Yellow Grease
- Spring for trip latch Assembly
- Pin UV/EA/SR release link
- Balmerol Moly ML grease(black)
- Lycom grease for jaw contact
- Facia retainer washers
- Maintenance Label
- Check List
- CRC Spray
- Split pin of main Spring
- Champion set, Plain multitype Screw Driver
- Same as - "D,Ring and T Pana - (6/7,8/9,10/11,12/13)
- Pillar Gauge for Breaker pole adjustment.
- Noise pliers and combinations pliers.
- Cotton for cleaning.
DRAWING
T1,T2,T3 - Protection CT
P2 - Ammeter
K1 - Motor Relay
X - 30 - 240V AC SUPPLY
X - 31 - (-Ve) Point
Q2 - 2poll AC MCB
For Zero Speed Switch 230V AC SUPPLY --:
X - 18 <-> +Ve Point
X - 19 <-> - Ve Point
{ For Space Heater use below the root }
X - 32 |-> 240V AC SUPPLY ]
X - 33 |-> (-ve) point
220V DC SUPPLY from Aux Busbar
X - 1 -> +Ve Supply
X - 2 ->. -Ve SUPPLY
Q3 - 220V DC SUPPLY MCB
240V AC from SP.HTR.BUS
X - 54 -> +Ve point
X - 55 -> -Ve Point
F11 - Fuse of 240V AC SUPPLY Positive side
X - 12 - Neutral link
FCR - Spring Charge Limit Switch
K2 - It is a MM00 Auxiliary Contactor. It's Use for Spring Charge Motor
15/16 - NO POINT - It is useing for
Lo19/20 - NC POINT - According the Cercuit it is useing for oparate the Closing Coil.When close in testing position or Start on ACB BREAKER Locally and Remotely.
23/24 - NO POINT - It is useing for Spring Charge indicator lamp.
220V DC SUPPLY through that roots --
F13 - Positive Side
F14 - Nagetive Side
K3 - MM00 Auxiliary Contactor. It is use for Antipumping closing Cercuit.
15/16 - NO POINT - It is Hold on point of own Cercuit.
19/20 - NC POINT - According the Cercuit it is useing for oparate the Closing Coil.When close in testing position or Start on ACB BREAKER Locally and Remotely.
K4 - It is a Lockout Relay.
1/2 - NC POINT - According the ACB Control Cercuit It is useing for Closing Coil.
7/8 - No Point - Spare
K5 - MM00 Auxiliary Contactor.
15/16 - NO POINT - According the Control Cercuit of ACB it is generally useing for main Common supply for Local and Remote selector Switch.
19/20 - NO POINT - It is useing for Auto trip indicator lamp.
23/24 - NC POINT - It is useing for Tripping Cercuit.
27/28 - NO POINT - According the Control Cercuit 24 DC SUPPLY through this roots towards the PLC RIOP panel.
It is useing for Fault Cercuit.
K6 - MM00 Auxiliary Contactor. When ACB BREAKER in service position the K6 Auxiliary also pickup.
15/16 - NO POINT - According the Cercuit It is useing for Tripping the ACB breaker.
19/20 - NO POINT - According the Cercuit 220V DC SUPPLY through out of fuse F13 . It is useing for Fault Cercuit Healthy.
23/24 - NO POINT - Spare
27/28 - NO POINT - Spare
K7 - MM00 Auxiliary Contactor. It is useing for
15/16 - NO POINT - SPARE
19/20 - NO POINT - It is useing for
23/24 - NO POINT - According the Control Cercuit 24 DC SUPPLY through this roots towards the PLC RIOP panel. It is also useing for ACB BREAKER on feedback.
27/28 - NO POINT - SPARE
PROBLEM FACED IN SYSTEM ROOTS -
If SPRINGCHARGING MOTOR not charging --:
To check the following roots -:
It is +ve fuse of 230V AC SUPPLY. Which is come out from X - 54
It is useing for Nagetive. it have come out from X - 55
It is a positive point.which have come out from F11 fuse and fix
at Breaker's sliding Contactor. Again 230V AC SUPPLY through in
this root to Spring Charge Motor.
It is the main rule to charge for Spring Charge Motor. According
the control Cercuit +ve supply take from F11 fuse side point to
coil of K2 (a) point.
It is use for nagetive. and connect with K2 (b) point. It is Spring Charge Limit Switch.
Sliding point. It is a nagetive side point which is coming from tb
number X - 55 . Again finally it's last end connect at FCR Spring
Charge Limit Switch.
It is a DC voltage Cercuit Posetive fuse. Again 220V DC Supply
come from Aux Bus. and connect at TB number X - 1 from Q3 MCB then
finally fix at F13 fuse. To check online DC voltage.or off check
continuity of the fuse
It is Nagetive point and it's coming from TB X-2 then Q3 MCB 3/4
then finally 220V DC Cercuit Nagetive Point fix at F14 fuse. again
a wire is connect at K5 Auxiliary Contactor coil supply (b) point.
It is a MM00 Auxiliary Contactor. and it is pick up when the
BREAKER in service position. Again to check it's K6 NO point 19/20
because 220v DC supply go through the roots.
It is also lockout relay. For confirmation to check DC voltage at
3/4 NC POINT.
It is a TB point. 220v DC Supply come out from K4 Lockout Relay
after healthy Ness fix at X - 3 TB point.
It is also K5 Auxiliary Contactor coil supply TB point. Again the
control supply come out from X - 3 TB . and supply through follow
the roots Em stop, PULLCARD switch which fall in between X - 3 and
X - 4. If for confirmation to check 220v DC online X - 4 to
Nagetive point.
F11
X-12
C
K2 Auxiliary Contactor mm00
H
FCR
D
If K5 Auxiliary Contactor not pick up -:
F13
F14
K6
K4
X-3
X-4
If CLOSING COIL OF ACB not Pick up
SHORTCUT TRICK
| PROBLEM | SHORTCUT for BYPASS |
|---|---|
| 24V DC COMMON SUPPLY | X - 20 |
| EM STOP | X - 20 to X1 - 1 |
| REMOTE | X - 20 to X1 - 2 |
| LEFT SIDE PULLCARD | X - 20 to X1 - 3 |
| RIGHT SIDE PULLCARD | X - 20 to X1 - 4 |
| LEFT SIDE BELTSWAY | X - 20 to X1 - 5 |
| RIGHT SIDE BELTSWAY | X - 20 to X1 - 6 |
| ZERO SPEED SWITCH | X - 20 to X1 - 7 |
| CONTROL SUPPLY FAILURE | X - 20 to X - 22 |
| FEEDBACK | X - 20 to X - 23 |
| FAULT | X - 20 to X - 25 |
If K5 Auxiliary Contactor not pick up -:
To check the following roots -:
F13 -
It is a DC voltage Cercuit Posetive fuse. Again 220V DC Supply come from Aux Bus. and connect at TB number X - 1 from Q3 MCB then finally fix at F13 fuse. To check online DC voltage.or off check continuity of the fuse
F14 -
It is Nagetive point and it's coming from TB X-2 then Q3 MCB 3/4 then finally 220V DC Cercuit Nagetive Point fix at F14 fuse. again a wire is connect at K5 Auxiliary Contactor coil supply (b) point.
K6 -
It is a MM00 Auxiliary Contactor. and it is pick up when the BREAKER in service position. Again to check it's K6 NO point 19/20 because 220v DC supply go through the roots.
K4 -
It is also lockout relay. For confirmation to check DC voltage at 3/4 NC POINT.
X - 3 -
It is a TB point. 220v DC Supply come out from K4 Lockout Relay after healthy Ness fix at X - 3 TB point.
X - 4 -
It is also K5 Auxiliary Contactor coil supply TB point. Again the control supply come out from X - 3 TB . and supply through follow the roots Em stop, PULLCARD switch which fall in between X - 3 and X - 4. If for confirmation to check 220v DC online X - 4 to Nagetive point.
To check the following roots -:
Typically, make sure the isolation position of the close and trip mechanisms is working properly.
To check resistance of closing coil or damage
TEST POSITION ROOTS —:
C8/Q1 -
It is a test position Limit Switch. The 220V DC Supply come from X - 1 and come out Q3 MCB and out the supply F13 Fuse side and the supply connect at one side of Test limit Switch.1/3 point.
S2 -
It is a manual close trip selector switch.again the control DC supply when test limit switch oparate the supply come out and fixing at IP - 1 number of close and Trip switch.
K3 -
Again K3 mm00 Auxiliary Contactor and it is useing for Antipumping closing Cercuit of ACB. It's NC 19/20 point is useing for oparate to close the Breaker's Closing Coil.
K2 -
It's 19/20 point is also useing to Breaker’s Closing Coil roots.
C6/Q1 -
It is a service limit switch of Breaker. When Breaker in service position the limit switch must be pick-up and voltage through the roots.
A/B -
It is Sliding point of Breaker. A point is useing for test position to pickuping the coil. B point is useing for Service position to pickuping the Closing coil.
Q1 -
It is a main Contactor of ACB breaker. Which is infront of inside the breaker. Again the supply through the NC point.
R -
It is a resistor of Breaker. Which is connect Breaker Sliding B point to Sliding N point. again the control supply go through the following roots.
N -
Again to repeat that mainly last sliding input point +Ve side of Breaker's Closing Coil. and supply also through in this roots.
E -
It is the negative root supply useing for closing coil of ACB breaker. Again the nagetive supply come out from F14 fuse and a wire is connect with Sliding point E.
K5 -
15/16 NO POINT is useing for 220V DC Common supply of ACB breaker. When the K5 Auxiliary Contactor pick up then NO point 15/16 also change to NC and supply go through the K1 Motor Relay 32/34 to the COMMON SUPPLY X - 7. Again it is useing at Local & Remote selector switch.
K1 -
It is a motor Relay of ACB BREAKER. It's 32/34 point use for common supply to X - 7
LOCALLY CERCUIT ROOTS -:
X - 7 -
Common supply point of ACB Breaker. Again when K5 Auxiliary Contactor pick up then the 220v DC SUPPLY show at common point X - 7
X -5 -
It is useing for LOCAL mode.
X - 6 -
Again X -5 and X -6 is sort together as per requirement.
X - 8 -
It is roots to close the Breaker's Closing Coil
REMOTE CERCUIT ROOTS —:
X - 9 -
It is useing for Remote mode.
X - 10 -
According the Cercuit X - 9 & X - 10 is sorting.
X - 11 -
It is useing for starting the breaker or Closing Coil.
K4 - NC point 1/2 -
It is also a Lockout Relay and it's NC point 1/2 come through the roots of closing coil.when trip the lockout relay the 220V DC Supply not come out from closing coil.
If Tripping Cercuit in not working.
To check the following roots -:
F15 -
It is a Positive Side which is come out from L1- 210 and the 220V DC supply connect at Fuse F15. So check the fuse and voltage.
F16 -
It is nagetive side of Breaker's.which is come out from L2-210
S2 -
ACB BREAKER Panel Close/Trip switch.
3 -
It is a Breaker's sliding point and it is a input positive side of Tripping Coil.
Q1 No Point -
Again it is a main Contactor of ACB breaker. After closing the breaker it's NO point is change to NC and it is ready to wait for a tripping command.
40 -
It is Nagetive point and connect at Tripping Coil.
K4 -
It is call as Lockout Relay. It's 5/6 NO point useing when the relay tripping.
K1 49/47 point -
It is motor Relay of ACB Breaker. If any fault in Breaker side the 220V DC Supply go through the 49/47 NO point to Tripping Coil.
X - 34 -
It is useing for Tripping cercuit input point.
X - 35 -
Output point of Tripping Cercuit.
K6 15/16 NO POINT -
It is MM00 Auxiliary Contactor. It's 15/16 NO point is useing for Tripping Cercuit or connect at (3) Sliding point.
X - 36 -
It is a input supply of EM.STOP.
X - 37 -
It is a output supply of Em.Stop. Again the 220 V DC Supply come out from Em.Stop roots connect at K6 Auxiliary Contactor input 15 point.
EMR.TRIP -
It is useing for Tripping.
X - 38 -
It is input point and connect at K5 Auxiliary Contactor 23 number. for Tripping.
X - 39 -
It is the output point of K5 24 number NC POINT which is useing for Tripping.
K5 23/24 NC POINT -
It is useing for Tripping cercuit input x - 38 to x - 39 roots.
X - 40 -
It is input Tripping Cercuit of Test position
X - 41 -
Output Tripping Cercuit of Test position.
K1 50/48 point -
The Tripping command from Motor Relay side.
K4 9/10 point -
Again the control supply come out from motor Relay and go through toward K4 Lockout Relay 9/10 NC Point from Tripping Cercuit Nagetive point of connect at Breaker's 40 number sliding point.
If Indication lamp not showing
To check the Follow the roots -:
F17 -
220V DC Supply posetive come out from L1 - 210 and connect with F17 fuse.
F18 -
The Nagetive point come out from L2 - 210 and connect at F18
H1 -
It is a ACB Breaker OFF Indication lamp.According the control Cercuit when the Breaker normal position. The supply go out and connect at Maincontacter Q1 5/6 NC point.again the supply through out from Q1 and connect at H1 indication lamp (11) Number.and (12) number is connect at F18 nagetive fuse side point.
H2 -
It is a ACB Breaker ON Indication lamp.According the control Cercuit when the Breaker Close position. The supply go out and connect at Main contactor Q1 7/8 NO point. Again the supply through out from Q1 and connect at H2 indication lamp (21) Number.and (22) number is connect at nagetive fuse F 18 side point.
H3 -
It is a ACB Breaker AUTO TRIP Indication lamp. According the control Cercuit when the K5 Auxiliary Contactor not pick up then The supply go out and connect at it's 19/20 NC point. Again the supply through out from K5 Auxiliary Contactor and connect at H3 indication lamp (31) Number.and (32) number is connect at nagetive fuse F 18 side point.
H4 -
It is an ACB breaker’s spring charge motor indication lamp. According to the control circuit, when the K2 auxiliary contactor is not picked up, the supply goes out and connects at its 23/24 NC point. Again, the supply comes out of the K2 auxiliary contactor and is connected to the H4 indication lamp (41) number, and the (42) number is connected to the nagetive fuse F18 side point.
IF REMOTELY ACB NOT STARTING -
1st check the normal status -
As a result, the pullcard EM.Stop is used for the ACB control circuit's overload circuit. Once more, only EM.Stop should be used in local mode. However, it is used by Pullcard Circuit and EM.Stop in remote mode. The ACB BREAKER will not start if any one of the options is selected.
The belt conveyor will not start remotely if the pullcard switch is not activated, and it will trip indicating a ZSS malfunction.
ZSS - ZERO SPEED SWITCH -
- It serves as a safety feature for belt conveyors. If the belt conveyor stops working or starts up again after a while.
- It is a safety device for belt conveyor.
- Turn the ZSS power switch on or off first. Check it out.
- 2nd check it's termination.
- 3rd check gap of sensor.
- Again check to confirm the zss and sensor manually oparate at JB side. When oparate a metal infront of the sensor the led blinking at ZSS switch. So that's to confirm the sensor work well.
- Verify ZSS RPM, POLE, and LB settings to ensure they meet requirements.
- When the BC-109 Breaker remotely starts and trips right away in the ZSS Fault, there is an issue. Once more, while verifying the ZSS settings, the startup delay setting is set to 9 seconds, yet the current running RPM value is 120, while the tripping RPM value is 101. Once more, the delay setting changes and increases in 9 to 12 seconds. Eventually, the issue is resolved, and the system operates without a hitch. (DT - 2nd may 2024)
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