L&T SWITCHGEAR

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ACB

MAINTENANCE, TROUBLE SHOOTING

TESTING OF RELEASES

E S P
SERVICE
MANUAL

AIR CIRCUIT BREAKERS

COMPLAINT

COMPLAINT

BREAKER IS NOT CLOSING

PROBABLE CAUSE

POSSIBLE SOLUTION

a) Undervoltage release not

connected with supply.
b) Undervoltage release, Shunt
release, Magneto thermal release
connecting link not adjusted
properly.
c) Magneto thermal release removed
from ACB, but trip bar of release
kept free.
d) Latch of the mechanism spring not
in proper position or misplaced.
e) Under voltage release coil burnt
out or open circuited.
f ) Bimetal element of magneto
thermal release bent permanently.
g) After overload or short circuit fault,
breaker not reset (ONLY FOR
MANUALLY RESET TYPE ACB.)
h) Sticking of tripping mechanism due
to excess dust.

a) Give rated voltage to under

voltage release.
b) Adjust the connecting linkage
of releases correctly.
c) Lock the trip bar at given
position.

d) Fix the spring correctly.

e) Replace the under voltage
release.
f ) Replace the magneto thermal
release.
g) Reset the breaker by pressing
OFF / RESET button.
h) Clean the tripping mechanism
with CRC 2-26 & grease them,
(refer section on greasing)

BREAKER IS NOT TRIPPING WITH UNDERVOLTAGE OR SHUNT RELEASE.

PROBABLE CAUSE

POSSIBLE SOLUTION

a) Shunt release does not get supply.

a) Check control wiring of

shunt release & ensure that
shunt release gets supply.
b) Check control wiring.

b) Supply of under voltage release

does not get cut off.
c) Link pins of Undervoltage or shunt
release misplaced.
d) Due to dust release becomes
sticky.

c) Ensure that pins are in

position.
d) Remove the dust from the
release & clean it with
CRC 2-26.

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MANUAL
COMPLAINT

COMPLAINT

COMPLAINT

BREAKER IS NOT TRIPPING BY MANUAL TRIP PUSH BUTTON

PROBABLE CAUSE

POSSIBLE SOLUTION

a) Trip push buttons connecting

link is short. (Not adjusted
properly.)
b) Latch of the mechanism.
jammed because of dust.

a) Adjust the push button link

correctly.
b) Clean the latch of the mechanism
with CRC 2-26.

ACB IS NOT TRIPPING IN CASE OF OVERLOAD OR SHORT CIRCUIT FAULT

PROBABLE CAUSE

POSSIBLE SOLUTION

a) Connection between C.T. and

magneto thermal release is
loose or open circuit.
b) Overload setting of magneto
thermal release is more than
actual load current.
c) Magneto thermal release
linkage not adjusted properly.

a) Tighten the terminals of C.T. in

case of open circuit.
b) Make the overload setting of ACB
as per actual load current.
c) Connect the linkage of magneto
thermal release to trip bar properly
& ensure its tripping operation.

MAIN CONTACTS OF ONE OF THE POLE OF ACB NOT CLOSING

PROBABLE CAUSE

POSSIBLE SOLUTION

a) Excessive dust accumulated

in the pole assembly.

a) Clean the pole assembly

mechanism with CRC 2-26.
Remove grease and dust with
brush & apply fresh grease.
b) Clean the nylon rollers with CRC
2-26 and relubricate them.
(refer section on greasing)
c) Consult the manufacturer of Circuit
Breaker
d) Consult the manufacturer of Circuit
Breaker.

b) Nylon rollers of the pole

assembly are not rotating
smoothly.
c) Pole connector setting
disturbed.
d) Nylon rollers of the pole
assembly are broken.

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MANUAL
COMPLAINT

COMPLAINT

PITTING ON MAIN CONTACTS

PROBABLE CAUSE

POSSIBLE SOLUTION

a) Arcing contact gap is not

adjusted properly.
b) Thickness of arcing contact is
reduced below the specified
limit. (> 0.5 mm)

a) Adjust the gap of arcing contacts,

it should be 0.9 + or -0.1 mm
b) Replace both fixed and moving
arcing contacts.

EROSION ON ARCING CONTACTS

PROBABLE CAUSE

POSSIBLE SOLUTION

a) Rough deion plates of arc

chutes.

a) Clean the deion plates and side

insulating strips of arc chutes with
CRC2-26.
b) Always operate ACB with arc chute in
position & keep the arc chutes clean

b) Breaker is operated without arc

chute in position.

COMPLAINT

COMPLAINT

BREAKER IS NOT RACKING IN THE CRADLE FREELY

PROBABLE CAUSE

POSSIBLE SOLUTION

a) Threads of mechanical
indicating assembly worn out.
b) Shutter assembly is not
properly set in the cradle.
c) Secondary isolating contacts
not matching properly.
d) Dovel pin broken.
e) Telescopic rail becomes
jammed.

a) Replace the mechanical indicating

assembly.
b) Fix the shutter assembly properly in
the cradle.
c) Match the fixed and moving
secondary isolation contacts properly.
d) Replace the dovel pin.
e) Clean the telescopic rail with CRC
2-26. Remove dust, grease &
relubricate it.

OVERHEATING
PROBABLE CAUSE

POSSIBLE SOLUTION

a) Poor termination (High MilliVolt drop across termination

on ACB.)

a) Clean the terminals with CRC 2-26

and do proper retermination. Ensure
that milli volt drop within specified
limits.
b) Do periodic cleaning of circuit breaker.
c) Use cables or bus bars of adequate
rating.
d) Reduce load current or select & install
correct rating of ACB.

b) Dusty atmosphere.
c) Use of undersized cable or
bus bars.
d) High ambient temperature.

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MANUAL
COMPLAINT

BREAKER IS NOT CHARGING WITH MOTOR

PROBABLE CAUSE

POSSIBLE SOLUTION

a) Motor is not getting supply.

a) Check the limit switch of motor.

Replace it if it is damaged.
b) Fix the secondary isolating
contacts properly,
c) Replace the motor.

b) Loose connections in
secondary isolating contacts.
c) Motor is burnt out.

COMPLAINT

BREAKER IS NOT CLOSING REMOTELY

POSSIBLE SOLUTION

POSSIBLE SOLUTION

a) Breaker is not in service

position
b) Closing coil is not getting
supply,
c) Closing coil burnt out or open
circuited.

a) Take the breaker in service

position.
b) Check control circuit and
ensure that coli gets supply.
c) Replace the closing coil,

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MANUAL

SERVICE OF ACBs
LITHON2
MOLYGREASE ML

PLATE 7
CRANK 6

COMPONENETS TO BE GREASED
P) PINS
1) ROLLER ASSEMBLY
2) POLE LATCH SPRING RETAINER
3) STAINLESS STEEL PROFILE
4) SLOTTED GUIDE
5) POLE LATCH NYLON ROLLERS
6) CRANK
7) PLATE
GREASE TO BE USED
1) LITHON 2 OF HINDUSTAN
PETROLEUM OR SYNTHOLUBE
10 OF H.J. LEACH
(FOR COMPONENTS SHOWN IN CIRCLE)
2) BALEMEROL MOLY GREASE ML OF
BALMER LAWRIE & CO.
(FOR COMPONENTS SHOWN IN SQUARE)
SCHEDULE FOR GREASING
EVERY 500 OPERATIONS OR 6 MONTHS
SECONDARY ISOLATING CONTACTS
SLIDING SURFACE OF FIXED & MOVING
CONTACTS WITH PETROLEUM JELLY

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MANUAL

GREASING
A Breaker normally greased and operating in a dust-free and non-corrosive
atmosphere over a period of two years can undergo its normal cycle of
mechanical endurance without greasing. As ideal service conditions are hardly
encountered, it is recommended to regrease the breaker after a cycle of 500
operations or six months, whichever is earlier.
COMPONENTS TO BE GREASED
All rubbing surfaces in the mechanism, poles etc. are to be greased except the
contacts (copper on copper) and sintered bearings. Prior to greasing, these surfaces
should be throughly cleaned. Excess grease must be wiped out.
Recommended
1. Lithon 2 of Hindustan Petroleum (Yellow)
grade of grease.

for pole parts FRCD gears in electrical breakers.

2. Balmerol Moly grease ML (Black) of Balmer Lawire & Co.
for mechanism in mechanical & electrical breakers.

COMPONENTS GREASED FOR LIFE

The following components are provided with self-lubricating sintered rings
impregnated with grease for life.
Trip rod
Intermediate shaft of manual control
Free-return charging device for electrical operation.
COMPONENTS NOT TO BE GREASED

All releases
Main isolating contacts and cradle terminals
Earthing terminal
Secondary isolating contacts

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SERVICE
MANUAL

PROPER TERMINATION TEST

TEST
Proper termination test of Cables, Busbars and Crimping of Cables can be tested by
measuring Milli-Volt drop across them. If the termination is not good, i.e. loose/
unclean/ less contact area then the joint resistance increases. The voltage drop
across such joints will be more as compared to a good joint.
Condition of contacts of any switchgear can be tested by measuring mV drop, across
them. If the contacts are pitted / unclean then contact resistance increases, so we get
high mV drop across them.

Typical Milli -Volt Drop Values

Joint Location

Test Current

Max. mV Drop

Amp.

Permissible

Terminal to Bus Barbar / Link

100

2.5

0.5 to 1

Terminal to Lug

50

8.0

1 to 2

Terminal to Lug

100

5.0

1 to 2

Rated

5.0

Cable to Cable Lug

Good mV Drop

(across crimping joint)

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SERVICE
MANUAL

8. OVERLOAD AND SHORT CIRCUIT TESTING OF ACB

1.

Trip the circuit breaker by pressing the trip push button of the release as shown
below.

Trip push button

T1 M1 T2 M2 T1 M1 T2 M2 T1 M1 T2 M2 S

1.0
0.9
0.75

This is necessary to check the mechanical setting of the release.

2.

As we will be testing circuit breaker by Secondary Injection Method, disconnect

all the wires from magneto thermal release.

3.

Set the release at point 1.0 for all three phase as shown below.

4.

Wire normally open (NO) auxiliary contact of ACB in series with test panel's
auxiliary contact. (This is to cut off the current flowing through the release as
soon as ACB trips.)

5.

Find out the rated CT secondary current. For L & T ACB rated CT secondary
current is 8.75 Amp.

Calculate the test current as follows :

*

For 2 times overload (200%)

Test current
=
Rated CT secondary current x No. of times of overload
=
8.75 x 2
=
17.50 amps

For 3 times overload (300%)

Test current
=
Rated CT secondary current x No. of times of oveload
=
8.75 x 3
=
26.25. amps

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MANUAL

OVERLOAD TESTING
Internal connections of the DN release with CT is shown in the following diagram.

SC
Magnetic
C xxx

O/L
Bime xxx

T1

M1

CT
R Phase

T2

M2

T1

M1

CT
Y Phase

Earning on C.B.

Note :

T2

M2

T2

M1

T2

M2

CT
B Phase

S
Shorting
link for
fixing E/F
release

For testing overload pass current between T1 % T2.

For testing short-circuit pass current between S & M1 or M2.

INTERNAL WIRING DIAGRAM OF NEW DN RELEASE

For overload testing we have pass current between T1 % T2 terminals of the release.
Contact the output terminals of the panel to T1 and T2 terminals of releases as
shown below (use 2.5 sq. mm copper wire).
To Current Source (Panel)

T1 M1 T2 M2 T1 M1 T2 M2 T1 M1 T2 M2 S

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MANUAL

Current vs Time (I-T) characteristic of DN type release is given below. Find out the
minimum and maximum trip time for 200% and 300% overload the curve and note it
down in table 1.

4000
2000
1000

1.05
OPERATING LIMITS THERMAL
1.2

500
300

TRIP TIME in sec.

200
100
50

Maximum trip
time curve

30
20
10

Minimum trip
time curve

5
3
2
1
0.5
0.3
0.9 1 1.1

1.3

6 7 8

10

12

16 18

MULTIPLES OF RATED CURRENT

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MANUAL

Switch on the supply and adjust the test current. Immediately switch off the current.
Keep the variac at adjusted position. Reset the time counter. Cool the release for
about 10 minutes.
Release setting = one

Sr. No.

Test Current (Amp)

Trip Time in Seconds

Actual
R

1.

17.50

2.

26.25

Remark
OK / Not OK
As per Curve

Min.

Max.

Table 1
Switch on the current and check trip time of the ACB. Fill up the data in above table.

SHORT CIRCUIT TESTING

i)

For short circuit testing, connect the output terminals of current control panel to
S and M1 or M2 terminals of release.

ii)

When M1 is connected test current should be 45 Amp and for M2 the test
current should be 57 Amp. (M1 and M2 magnetic threshold are of the order
500% to 700% of CT secondary.)

iii)

Close the breaker.

iv)

Switch on the current and check for instantaneous tripping operation of

breaker.

Note : Connect the wires of magneto thermal release as per wiring diagram.

Sr. No.

Test Current (Amp)

Trip Time in Seconds

Remark
OK / Not OK

Actual
R
1.

M1

45

2.

M2

57

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SERVICE
MANUAL

MICROPROCESSOR BASED RELEASE SR 21

The self powered SR 21 release has four zones of
protection
1.

Protection against overload : Long Time

2.

Protection against short circuit : Short Time

3.

Protection against short circuit : Instantaneous

4.

Protection against Earth fault : Ground fault

The release is fed by three current tranformers with

nominal CT secondary current 750 mAmp.
The release provides, choice of characteristics
suitable to load characteristics.
It is provided with thermal memory switch.
On changing the position of this switch to ACTIVE
POSITION the release provides COLD & HOT
characteristics.
The release also displays the type of fault under which the breaker trips through its
indicators. The indicators reset when breaker is reclosed and a current of about 15%
of breaker rating starts flowing.
Remote & Separate fault indication can be achieved through annunciation module.
The settings must be changed only with the release is in OFF condition. Any change
during ON condition will not be recognised by the release.
Breaker with SR 21 releases can be interconnected for Zone Selective Interlocking
(ZSI), which provides discrimination between upstream & downstream breakers
during short time (short circuit) & earth fault conditions.
Recommended wiring between ACBs for ZSI : PVC sheathed shielded twisted pair
wire 7/0.2 tinned copper. SICs SI (for short time) & GI (for ground fault) of the
upstream breaker are to be wired to SICs SO (for short time) & GO (for ground fault)
respectively of the down stream breaker.
Wiring between two breakers for
Zone selective interlocking :
A & B are ACBs interconnected for
ZSI. For fault at location X ACB B
trips instantaneous & A Trips after
delay if B fails to trip. For fault at
location Y ACB A trips after default
delay of 60 ms plus breaker
operating time instead of time
delay set on release.

SO
SI
GO Breaker

OI
O

Y
B

SO
SI
GO Breaker

OI
O

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MANUAL

MICROPROCESSOR BASED SR 21 RELEASE

SR 21
LONG TIME

0.50

0.95

0.65

0.90

0.70

0.85

30

0.5

17

1.0

12

1.5
6
3.5

xln

10

2.0

sec. at 6 lr

4
SHROT TIME

20

2
3

PICK UP
10

5
8

INSTANTANEEOUS

60

600
500

100

400

160

300

200
260

xln

11

ms

2
3

PICK UP

DELAY

6
7

lr

DELAY

0.75
0.80

lr

0.2
0.60

1.00

PICK UP

10

5
8

6
7

lr

12
xln

6
GROUND FAULT
PICK UP

8
400

0.4

200

13

300

ms

xln

lr
POWER

DELAY

0.3

0.6
0.5

100

0.2

TEST

MEMORY

14

8
ACTIVE BLOCKED

LARSEN & TOUBRO LIMITED

1. Long Time Current Pick-up switch.

9.

2. Long Time Delay switch.

10. Long Time Trip indicator (LT)

3. Short Time Current Pick-up switch.

11 . Short Time trip indicator (ST)

4. Short Time Delay switch.

12. Instantaneous trip indicator (INS)

5. Instantaneous Current Pick-up switch.

1 3. Ground Fault trip indicator (GF)

6. Ground Fault Current Pick-up switch.

14. Thermal Memory ACTIVE/BLOCKED

7. Ground Fault Delay switch.

Power ON LED

switch (Sliding switch type)

8. Trip function test connector

In

Nominal Current i.e. C.T. tap value

lr

Rated current i.e. selling of pick up current

for long time in the release.

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MANUAL

L O N G T I M E D E L AY F O R S R 2 1

10000

1000

TRIP TIME in sec.

100

10

0.1

0.01
1.2

1.5

10

14

20

MULTIPLES OF RATED CURRENT

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MANUAL

MICROPROCESSOR BASED RELEASE SR 61 C

The microprocessor based, communication capable release gives following
protections.
1.

Protection against overload : Long Time

2.

Protection against short circuit : Short Time

3.

Protection against Earth fault : Ground fault

The release continuously measure & displays in

scrolling way.
a]

The 3 phase RMS Current.

b]

Earth leakage current.

The non-valatile memory of release stores & displays :

i]

Last 5 trip data i.e. trip cause & current values.

ii] The number of tripping due to a particular fault.

iii] The RMS values of current measured during
switch-on of feeder.
The fault indication is through 4 LEDs which indicates the phase in which fault has
occurred. LEDs starts flashing while sensing the fault & go steady when the trip has
occurred. The indication is reset manually through reset push button.
SR 61 C Release has five outputs contacts :
R1 Used for trip output. It actuates the flux shift device which directly actuates the
tripping mechanism. (R1 can be programmed for manual/auto reset and is not
available outside for writing)
R2 It is an instantaneous output element, which can be used as blocking output, to
avoid nuisance tripping of upstream ACB.
R3 It is used for closing the ACB, through closing coil.
(R3 & R4 are used to operate the ACB from remote location in communication
mode say, through computer)
R4 This release use for internal fault condition. It de-energizes when the control
supply fails or internal malfunction occurs. The release automatically checks its.
Under internal fault, the error LED glows, fault code in seven segment is displayed.

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