BC - 109

BELT CONVEYOR - 109

ITEM	BC - 109
PANEL NUMBER	3f -
PANEL. SIDE	PMCC - 3
JB SIDE	JH - 6
TYPE	ACB
KW	200
HP	215
FUSE RATING	ACB
POLE	4
VOLTAGE	415
F1. AMP	260
RPM	1490
SFU RATING	800A
FRAME	ND 315L
BEARING DESIGN	6319C3
FLC	324

 

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

Activity after the outage :

• Energize switchgear and verify normal operation
• Remove Signs,
• Prepare a report of maintenance and test results.

Content of the Service Kit :

1. Self Carbon check list.
2. Cloth for cleaning (Chese Cloth)
3. Cloth for Cleaning Contact
4. Scruber (Sctoch Brite)
5. Hand gloves
6. Wire Cerclip 4,5,6 Mm
7. Lithon Yellow Grease
8. Spring for trip latch Assembly
9. Pin UV/EA/SR release link
10. Balmerol Moly ML grease(black)
11. Lycom grease for jaw contact
12. Facia retainer washers
13. Maintenance Label
14. Check List
15. CRC Spray
16. Split pin of main Spring
17. Champion set, Plain multitype Screw Driver
18. Same as - "D,Ring and T Pana - (6/7,8/9,10/11,12/13)
19. Pillar Gauge for Breaker pole adjustment.
20. Noise pliers and combinations pliers.
21. Cotton for cleaning.

DRAWING 

SCAN THE BARCODE - 

PULLCARD - 

DETAILS OF ACB BREAKER'S -:

Q1 - Main Contactor

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 and RECTIFY

1. 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)

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