Installation_ing_Troublesho Side By MSD2356AEA Installation Ing Troubleshooting Starters Overload Relays
User Manual: Side by Side MSD2356AEA
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L&T SWITCHGEAR SAFE & SURE OVERLOAD RELAYS, STARTERS TESTING, INSTALLATION & TROUBLE SHOOTING. E S P SERVICE MANUAL TESTING OF THERMAL OVERLOAD RELAY 1. Fill up the following data of relay under test. a) Relay Type _____________________ b) Relay Range ____________________ c) Max. Back up fuse rating __________ 2. Check continuity of auxiliary contacts and main poles. a) Normally open __________________ b) Normally closed _________________ c) R Pole ________________________ d) Y Pole _________________________ NOTE : If the answer is O.K. to all above points then only take the relay for overload testing. 3. Select the proper size of cable for connection. In case of smaller size of cable or improper termination, relay may trip early. 4. Connect all three poles of relay in series as shown in the following diagram. Use proper size of cables. Length of cable should be one metre. 5. Connect normally closed (NC) contact of relay in series with test panel's auxiliary contact. (This will give relay trip to test panel.) OVERLOAD TEST FROM CURRENT SOURCE 1m 1m DUT 1m 'NC' CONTACT OF RELAY 1m Connections of Thermal Overload Relay for O/L Testing L&T SWITCHGEAR SAFE & SURE 30 E S P SERVICE MANUAL 6. Set the relay and calculate the test current as follows: Relay Setting X Multiples of Set Current (% of overload) = Test Current Amps 20 Amps Eg.: 10 Amps. X 2(200%) = 1. X 2(200%) = 2. X 3(300%) = 7. Find out the minimum and maximum trip time with respect to multiples of set current you have selected and note down the values in the following table. Sr. No. Relay Setting Test Current (Amp) Trip Time in Seconds i-t characteristics. Actual As per Curve Min. Remark OK / Not OK Max. 1. 2. 8. Switch on the supply and adjust the test current. Immediately switch off the current. Keep variac at adjusted position. Reset the time counter. Cool the relay for about 10 minutes. 9. Switch on the test current and check trip time of the relay. Caution After each test, cool the relay for minimum 10 minutes. Otherwise, relay will trip early and you will not get correct results. Cable size with respect to test current. Test Current Amp 0 to 15 15 to 30 30 to 46 For Copper Cables sq. mm 1 1.5 4 46 to 66 66 to 110 6 10 100 to 150 150 to 220 25 35 L&T SWITCHGEAR SAFE & SURE 31 E S P SERVICE MANUAL SINGLE PHASING TEST FROM CURRENT SOURCE 1m DUT 1m 'NC' CONTACT OF RELAY 1m CONNECTIONS OF THERMAL OVERLOAD RELAY FOR SINGLE PHASE TESTING Sr. No. Relay Setting Test Current (Amp) Trip Time in Sec. from i-t characteristics. Min. Actual Remark OK / Not OK Max. 1. 2. L&T SWITCHGEAR SAFE & SURE 32 E S P SERVICE MANUAL TRIPPING CURVE FOR MK1 / ML1 RELAYS FOR RANGES UPTO 6-10 AMPS. 4000 2000 1000 600 TRIPPING TIME IN SECONDS 400 200 100 60 50 40 30 20 10 6 4 2 0.8 1 1.2 1.5 2 3 4 5 6 7 8 MULTIPLES OF SET CURRENT NOTE : 1. THE TRIPPING TIME FOR ANY CURRENT SHALL LIE BETWEEN THE VALUES CORRESPONDING TO 90% AND 110% OF THAT CURRENT. 2. CURVE REPRESENTS COLD STATE CHARACTERISTICS. L&T SWITCHGEAR SAFE & SURE 33 E S P SERVICE MANUAL TRIPPING CURVE FOR MK1 / ML1 RELAYS FOR RANGES UPTO 9-14 & 10-16 AMPS. 7200 6000 4000 2000 1000 600 TRIPPING TIME IN SECONDS 400 200 100 60 50 40 30 20 10 6 4 2 0.8 1 1.2 1.5 2 3 4 5 6 7 8 MULTIPLES OF SET CURRENT NOTE : 1. THE TRIPPING TIME FOR ANY CURRENT SHALL LIE BETWEEN THE VALUES CORRESPONDING TO 90% AND 110% OF THAT CURRENT. 2. CURVE REPRESENTS COLD STATE CHARACTERISTICS. L&T SWITCHGEAR SAFE & SURE 34 E S P SERVICE MANUAL TRIPPING CURVE FOR ML2 / ML3 RELAYS 7200 6000 4000 2000 1000 600 TRIPPING TIME IN SECONDS 400 200 MAXI. TRIP TIME CURVE 100 60 50 40 30 MINI. TRIP TIME CURVE 20 10 6 4 2 0.8 1 1.2 1.5 2 3 4 5 6 7 8 MULTIPLES OF SET CURRENT NOTE : CURVE REPRESENTS COLD STATE CHARACTERISTICS. L&T SWITCHGEAR SAFE & SURE 35 E S P SERVICE MANUAL TRIPPING CURVE FOR MN RELAYS ON 3 POLE LOADING (BALANCED) CONDITION 10000 4000 2000 TRIPPING TIME IN SECONDS 1000 400 MAX. TRIP TIME CURVE 200 115 SEC. 100 48 SEC. 40 20 MINI. TRIP TIME CURVE 10 2 0.8 1 1.5 2 3 4 5 6 7 8 9 10 MULTIPLES OF SET CURRENT NOTE : CURVE REPRESENTS COLD STATE CHARACTERISTICS. L&T SWITCHGEAR SAFE & SURE 36 E S P SERVICE MANUAL TRIPPING CURVE FOR MN REL AYS ON 2 POLE LOADING (SINGLE PHASING) CONDITION 10000 4000 2000 1000 TRIPPING TIME IN SECONDS 400 200 100 60 SEC. 40 20 11 SEC. 10 6 4 2 0.8 1 1.5 2 3 4 5 6 7 8 9 10 MULTIPLES OF SET CURRENT NOTE : CURVE REPRESENTS COLD STATE CHARACTERISTICS. L&T SWITCHGEAR SAFE & SURE 37 E S P SERVICE MANUAL TRIPPING CURVE FOR MN12 L RELAYS ON 3 POLE BALANCED LOADING CONDITION 104 TRIPPING TIME IN SECONDS 10 3 MAX. SETTING 102 MIN. SETTING 101 0.6 1.2 1.5 2 3 4 6 8 10 MULTIPLES OF SET CURRENT L&T SWITCHGEAR SAFE & SURE 38 E S P SERVICE MANUAL WIRING DETAILS MN25, MN32 DOL MN16 DOL MN45, MN65 DOL L&T SWITCHGEAR SAFE & SURE 39 E S P SERVICE MANUAL WIRING DETAILS MN16 FASD MN16 SASD MN25, MN32 FASD MN25, MN32 SASD L&T SWITCHGEAR SAFE & SURE 40 E S P SERVICE MANUAL WIRING DETAILS MN45, MN65 FASD MN80, MN110, MN140 FASD L&T SWITCHGEAR SAFE & SURE 41 E S P SERVICE MANUAL WIRING DETAILS ML1 DOL ML1.5 DOL ML1.5 FASD ML1.5 SASD L&T SWITCHGEAR SAFE & SURE 42 E S P SERVICE MANUAL WIRING DETAILS ML2 FASD ML2 SASD ML3 FASD ML3 SASD L&T SWITCHGEAR SAFE & SURE 43 E S P SERVICE MANUAL WIRING DETAILS ML4, ML6 FASD ML10, ML12 FASD L&T SWITCHGEAR SAFE & SURE 44 E S P SERVICE MANUAL WIRING DETAILS MF1 DOL (3 PHASE) STARTERS MF1 DOL (3 PHASE) STARTERS FOR SINGLE PHASE LOADS MF1 DOL (SINGLE PHASE) STARTERS L&T SWITCHGEAR SAFE & SURE 45 E S P SERVICE MANUAL WIRING DETAILS MK1 DOL MK1 FASD MK1 SASD L&T SWITCHGEAR SAFE & SURE 46 E S P SERVICE MANUAL S TA R D E LTA S TA R T E R S ( M L S E R I E S ) Details of Contactors and timers used in ML series star delta starters Starters Timers Contactors STAR DELTA HOLD ON ML 1.5 SASD ML 1 ML 1.5 ML 1.5 — ML 1.5 FASD ML 1 ML 1.5 ML 1.5 GT-200 ML 2 SASD ML 2 ML 2 ML 2 — ML 2 FASD ML 2 ML 2 ML 2 GT-200 ML 3 SASD ML 2 ML 3 ML 3 — ML 3 FASD ML 2 ML 3 ML 3 ET-100 ML 4 FASD ML 3 ML 4 ML 4 ET-100 ML 6 FASD ML 4 ML 6 ML 6 ET-100 ML 10 FASD ML 10 ML 10 ML 10 ET-100 ML 12 FASD ML 12 ML 12 ML 12 ET-200 L&T SWITCHGEAR SAFE & SURE 47 E S P SERVICE MANUAL CHART FOR DOL MOTOR STARTERS WITH ML RELAYS Motor Rating 240V-1 Phase Sr. No hp kW In (A) 1 0.125 0.09 0.45 0.4-0.65 2 0.15 0.11 0.45 3 0.2 0.15 4 0.25 5 Contactor Back up fuse SDF Rating Type MLO 2 HF FN32 0.4-0.65 MLO 2 HF FN32 0.57 0.4-0.65 MLO 2 HF FN32 0.19 0.7 0.6-1.0 MLO 4 HF FN32 0.33 0.25 0.88 0.6-1.0 MLO 4 HF FN32 0.5 0.37 1.2 1.0-1.6 MLO 6 HF FN32 0.75 0.55 1.6 1.5-2.5 MLO 6 HF FN32 1.0 0.75 1.8 1.5-2.5 MLO 6 HF FN32 1.25 0.92 2.1 1.5-2.5 MLO 8 HF FN32 1.5 1.1 2.6 2.5-4.0 MLO 10 HF FN32 11 1.75 1.3 3.0 2.5-4.0 MLO 10 HF FN32 12 2.0 1.5 3.5 2.5-4.0 MLO 10 HF FN32 2.5 1.8 4.8 4-6.5 MLO 16 HF FN32 14 3.0 2.2 5.0 4-6.5 MLO 16 HF FN32 15 4.0 3.0 6.2 4-6.5 MLO 16 HF FN32 0.125 In Relay Range hp 6 kW Motor Rating 215V-3 Phase 0.11 7 8 0.25 0.18 2.0 9 10 13 0.5 0.75 0.4 0.55 3.6 L&T SWITCHGEAR SAFE & SURE 48 E S P SERVICE MANUAL CHART FOR DOL MOTOR STARTERS WITH ML RELAYS Motor Rating 240V-1 Phase Sr. No hp Motor Rating 215V-3 Phase kW In hp kW Relay Range In (A) Contactor Back up fuse Rating Type SDF 16 1.0 0.75 7.5 5.0 3.7 7.5 6-10 MLO 20 HF FN32 17 1.25 0.9 8.0 6.0 4.5 9.0 6-10 MLO 25 HF FN32 18 2.0 1.5 9.5 7.5 5.5 11.0 10-16 MLO 25 HF FN32 19 3.0 2.25 14.0 10.0 7.5 14.0 10-16 ML1 32 HF FN32 20 12.5 9.3 18.0 13-21 ML1.5 50 HF FN63 21 15.0 11.0 21.0 20-32 ML1.5 63 HF FN63 22 17.5 13.0 24.0 20-32 ML2 63 HF FN63 23 20.0 15.0 28.0 20-32 ML2 63 HN/00 FN100 24 25.0 18.6 35.0 28-42 ML3 80 HN/00 FN100 25 30.0 22.5 40.0 28-42 ML3 80 HN/00 Fn100 NOTES: (1) The full load currents given apply in the case of single phase motors, to capacitor-start type motors and in the case of 3 phase motors, to squirrel cage type induction motors at full load having average power factor and efficiency. The motors should have speeds not less than the following: Upto 10 hp - 750 R.P.M., 10 to 30 HP - 600 R.P.M., 30 - 125 HP - 500 R.P.M., 125 - 300 HP - 375 R.P.M. (2) Contactors/Switches indicated are the minimum ratings suitable for the application. Higher sizes/Ratings can be used. (3) Normal motor starting times are assumed in all cases. L&T SWITCHGEAR SAFE & SURE 49 E S P SERVICE MANUAL C H A R T F O R S TA R - D E LTA M O T O R S TA R T E R S WITH ML RELAYS Motor Rating Sr. No Current at 415 V (A) Relay Range Nominal Back up fuse link Contactor SDF hp kW LINE PHASE (A) STAR LINE DELTA Rating A Type/ Size 1 1 0.75 1.8 1.04 1-1.6 MLO MLO MLO 4 HF FN32 2 1.5 1.1 2.6 1.5 1-1.6 MLO MLO MLO 6 HF FN32 3 2 1.5 3.5 2.02 1.5-2.5 MLO MLO MLO 6 HF FN32 4 3 2.25 5 2.88 2.5-4.0 MLO MLO MLO 8 HF FN32 5 4 3 6.2 3.58 2.5-4 MLO MLO MLO 10 HF FN32 6 5 3.75 7.5 4.32 4-6.5 MLO MLO MLO 16 HF FN32 7 6 4.5 9 5.2 4-6.5 MLO MLO MLO 16 HF FN32 8 7.5 5.5 11 6.34 6-10 MLO MLO MLO 20 HF FN32 9 10 7.5 14 8.08 6-10 MLO MLO MLO 20 HF FN32 10 12.5 9.3 18 10.04 10-16 MLO MLO MLO 32 HF FN32 11 15 11 21 12.1 10-16 MLO Ml1 Ml1 32 HF FN32 12 20 15 28 16.2 13-21 ML1 ML1.5 ML1.5 40 HF FN63 13 25 18.5 35 20.2 13-21 ML1 ML1.5 ML1.5 50 HF FN63 14 30 22.5 40 23 20-32 ML2 ML2 ML2 63 HF FN63 15 35 26 47 27 20-32 ML2 ML2 Ml2 63 HN/00 FN100 16 40 30 55 31.8 28-42 ML2 ML3 ML3 63 HN/00 FN100 17 45 33.5 60 34.6 28-42 ML2 ML3 ML3 80 HN/00 FN100 18 50 37.5 66 38.2 28-42 ML2 ML3 ML3 80 HN/00 FN100 NOTES: (1) Contactors/Switches indicated are the minimum ratings suitable for the application. Higher sizes/Ratings can be used. (2) For applications above 35 hp suitable scheme to be employed to ensure change over delay of 40-75ms between star and delta contactors. (3) Normal motor starting times are assumed in all cases. L&T SWITCHGEAR SAFE & SURE 50 E S P SERVICE MANUAL CHART FOR MF1 THREE PHASE / SINGLE PHASE Motor rating in hp Relay scale Maximum safe rating of back-up fuses* 415V 3 phase Amps (A) Cartridge fuses Rewritable fuses SWG 0.125 0.4-0.65 4A 35 0.25 0.6-1.0 6A 32 0.5 1.0-1.6 6A 32 0.75 1.5-2.5 16A 25 1.0 1.5-2.5 16A 25 1.25 1.5-2.5 16A 25 1.5 2.5-4.0 25A 23 1.75 2.5-4.0 25A 23 2.0 2.5-4.0 25A 23 2.5 4.0-6.5 25A 23 3.0 4.0-6.5 25A 23 4.0 4.0-6.5 25A 23 0.75 4.5-7 25A 23 1.00/1.25 6.5-11 32A 21 5.0 6.0-10 32A 21 6.0 6.0-10 32A 21 10.5-17.5A 32A 21 9.0-15 32A 21 11-18 32A 21 12-20A 32A 21 240V Single phase 0.125 0.25 0.5 2.00 7.5 3.00 * Cartridge type fuses are recommended L&T SWITCHGEAR SAFE & SURE 51 E S P SERVICE MANUAL CHART FOR Mk1 DOL STARTER Motor rating H.P. Cat No. 220 1-Phase 400V 3-phase 440V 4-phase 0.005 0.05 0.15-0.25 1A 0.1 0.1 0.25-0.4 2A 0.125 0.125 0.25-0.4 2A 0.15 0.15 0.4-0.65 4A 35 0.2 0.2 0.4-0.65 4A 35 0.25 0.4-0.65 4A 35 0.6-1.0 6A 0.5 1.0-1.6 0.75 0.25 0.75 SS96210 0.5 32 6A 32 6A 32 6A 32 1.0-1.6 6A 32 6A 32 1.0 1.5-2.5 15A 25 6A 32 1.0 1.25 1.5-2.5 15A 25 6A 32 1.25 1.5 2.5-4.0 25A 23 10A 28 1.5 1.75 2.5-4.0 25A 23 10A 28 1.75 2.0 2.5-4.0 25A 23 10A 28 2.5-4.0 25A 23 10A 28 0.5 Diazed Minimum SWG 2.0 0.75 Maximum Diazed 0.25 0.125 Back-up Fuse Rating Relay Amps. Range SWG 2.5 2.5 4.0-6.5 25A 23 10A 28 3.0 3.0 4.0-6.5 25A 23 10A 28 4.0 4.0-6.5 25A 23 10A 28 6-10 35A 21 15A 25 1.0 4.0 1.25 5.0 5.0 6-10 35A 21 15A 25 1.5 6.0 6.0 6-10 35A 21 15A 25 9-14 35A 21 15A 25 1.75 2.0 7.5 7.5 11-18 35A 21 15A 25 SS96211 2.0 7.5 7.5 11-18 35A 21 15A 25 SS96228 2.0 7.5 7.5 13-22 40A 21 15A 25 Note : Amp. Rating of back-up fuse refers to the recommended diazed type HRC catridge fuse. Where rewirable semi-enclosed, tinned copper wire fuses are used, SWG number in table is approximate guide to size of wire required. L&T SWITCHGEAR SAFE & SURE 52 E S P SERVICE MANUAL C H A R T F O R M K 1 S TA R - D E LTA S TA R T E R Cat No. Motor Full load Rating line 400/440v current 3-phase in Amps. hp ln In V3 Relay Amps. Range Back-up Fuse Rating Maximum Minimum Diazed SWG Diazed SWG 1 1.7 1 1-1.6A 6 32 4 35 1.5 2.4 1.4 1-1.6A 15 25 6 32 2 3.1 1.8 1.5-2.5A 15 25 6 32 SS96254 3 4.4 2.5 2.5-4A 25 23 6 32 & 4 5.7 3.3 2.5-4A 25 23 10 28 SS96255 5 7.1 4.1 4-6.5A 25 23 10 28 6 8.4 4.9 4-6.5A 25 23 10 28 7.5 10.4 6 6-10A 35 21 15 25 10 13.6 7.9 6-10A 35 21 15 25 12.5 17 9.7 9-14A 35 21 20 24 15 19.9 11.5 9-14A 35 21 25 23 15 19.9 11.5 11-18A 35 21 25 23 SS96257 & SS96258 Note: Amp. Rating of back-up fuse refers to the recommended diazed type HRC catridge fuse. Where rewirable semi-enclosed, tinned copper wire fuses and used, SWG number in table is approximate guide to size of wire required. Cat. No SS 96254 & SS 96257 - FASD Starters Cat. No SS 96255 & SS 96258 - SASD Starters L&T SWITCHGEAR SAFE & SURE 53 E S P SERVICE MANUAL SELECTION CHART FOR MU/MBDOL STARTERS Type MB1 DOL MB2 DOL MU1 DOL MU2 DOL Maximum Motor rating at 145V.3 ph 50 HZ HP KW 7.5 5.5 Approx. Full load Current in 11 Relay Range (A) Relay Contactor 9-15 10 7.5 14 14-23 12.5 9.3 18 14-23 15 11 21 14-23 15 11 21 20-33 7.5 5.5 11 9-14 10 7.5 14 13-21 12.5 9.3 18 13-21 15 11 21 13.21 15 11 21 20-32 MN2 MN2 MU2 MU2 MU1 MU2 MU1 MU2 Back-up HRC Fuse Switch Disconector Fuse Unit Type Rating (A) HF 32 FN 32 HF 50 FN 63 HF 50 FN 63 HF 63 FN 63 HF 63 FN 63 HF 32 FN 32 HF 50 FN 63 HF 50 FN 63 HF 63 FN 63 HF 63 FN 63 S E L E C T I O N C H A R T F O R M U / M B S TA R D E LTA S TA R T E R S Type MB1 SASD MB2 SASD MU1 SASD MU2 SASD Maximum Motor rating at 145V.3 ph 50 HZ HP KW 15 11 Approx. Phase Relay Full load Current Range Current in (A) 21 12.1 Relay Contactor 9-15 15 11 21 12.1 14-23 20 15 28 16.2 14-23 25 18.5 35 20.2 14-23 30 22.5 40 23 20-33 15 11 21 12.1 9-14 15 11 21 12.1 13-21 20 15 28 16.2 9-14 25 18.5 35 20.2 13-21 30 22.5 40 23 20-32 MN2 MN2 MU2 MU2 MU1 MU1 MU1 MU2 Back-up HRC Fuse Switch Disconector Fuse Unit Type Rating (A) HF 32 FN 32 HF 40 FN 63 HF 40 FN 63 HF 50 FN 63 HF 63 FN 63 HF 32 FN 32 HF 40 FN 63 HF 40 FN 63 HF 50 FN 63 HF 63 FN 63 L&T SWITCHGEAR SAFE & SURE 54 E S P SERVICE MANUAL SELECTION CHART FOR MUG-10 DOL SUBMERSIBLE PUMP STARTERS Type Maximum submersible pump rating at 415 V, 3ph., 50hz HP Relay Range (A) KW Relay Contactor Type Type Type Rating (A) Back-up HRC Fuse Switch Disconnector Fuse Unit 3 2.2 4-6.5 MU 1 MU 1 HF 16 FN 32 5 3.7 6-10 MU 1 MU 1 HF 16 FN 32 7.5 5.5 9-14 MU 2 MU 1 HF 32 FN 32 10 7.5 13-21 MU 2 MU 1 HF 40 FN 63 5 3.7 6-10 MN 2 MU 1 HF 16 FN 32 7.5 5.5 9-15 MN 2 MU 1 HF 32 FN 32 10 7.5 20-32 MU 2 MU 2 HF 63 FN 63 10 7.5 28-42 MU 2 MU 2 HN/00 63 FN 100 MUG-10 DOL MUG-10N DOL MUG-10H DOL* * - Controllers for low voltage application Note : MU 1/2 contactors are available in 415 V coil operating voltage also. Note : MUG-10 DOL are available with dry run facility as a optional feature. L&T SWITCHGEAR SAFE & SURE 55 E S P SERVICE MANUAL S E L E C T I O N C H A R T F O R M U G - 2 0 S TA R - D E LTA SUBMERSIBLE PUMP STARTERS Type Maximum submersible pump rating at 415 V, 3ph., 50hz Relay Range (A) Relay Contactor Type Type Type Rating (A) Back-up HRC Fuse Switch Disconnector Fuse Unit HP KW MUG-20 15 11 9-14 MU 2 MU 1 HF 32 FN 32 Star-Delta 20 15 13-21 MU 2 MU 1 HF 40 FN 63 MUG-20H* 20 15 20-32 MU 2 MU 2 HF 63 FN 63 Star-Delta 20 15 28-42 MU 2 MU 2 HN/00 63 FN 100 * - Controllers for low voltage application Note : MU 1/2 contactors are available in 415 V coil operating voltage also. Note : MUG-10 DOL are available with dry run facility as a optional feature. L&T SWITCHGEAR SAFE & SURE 56 E S P SERVICE MANUAL INFORMATION FOR INSTALLATION AND PREVENTIVE MAINTENANCE Cable connections to the terminals When aluminium wires are used, the following method should be adopted: If the wire is small up to 1 mm 2 – Single strand 1. Clean the wire surface by rubbing with a small hard wire brush. 2. Tin the wire immediately (within 2 or 3 minutes). 3. Put wire under terminal clamp and tighten screws. Do not tighten to such an extent that the wire becomes flat. Every two or three months, it may be necessary to ensure that the screws are tight and the wire has not become loose. This may happen because aluminium is soft and is likely to “flow”. Always apply inhibiting grease around the terminal and wire to prevent moisture from reaching the area of contact. Apply inhibiting grease, only on the terminals and wire and not on the contacts. If the wire is large – larger than 10 mm2 – Multi-strand Wires should be connected with the help of cable lugs or thimbles. The cable lugs may be of "soldering" or "crimping" type. For "soldering" type cable lugs: • Check that cable lug socket is clean and dry inside. • Clean every strand of aluminium wire with a small hard wire brush by opening out the cable strands. • Immediately dip all the strands in tin solder. • Insert the stranded cable in the proper size cable lug and pour solder through the cable lug. Ensure that solder fills the entire space inside the cable lug socket. • Wipe off excess solder on cable insulation. • Connect the cable lug to the terminal and tighten terminal screws using spring washers on the cable lug. • There should not be excess load on the cable lug, or else the solder will become loose. Care must, therefore, be taken to cut the cable core and strip the insulation to the correct length. The cable lug should sit flat on the terminal and the cable should not have sharp bends. Every two or three months it is necessary to check whether the connection is firm and to tighten the screws, if necessary. Also check and ensure that the cable is not loose in the cable lug. L&T SWITCHGEAR SAFE & SURE 57 E S P SERVICE MANUAL For "crimping" type cable-lugs : • Check that cable lug socket is clean and dry inside. • Clean every strand of aluminium wire with a small hard wire brush after opening strands. • Close the strand again immediately, insert to the proper length inside the cable lug socket and crimp, using the correct crimping tool. • Connect the cable lugs to the terminal and tighten terminal screws using spring washers on the cable lug. Contact maintenance Contact tips are made of silver compositions like silver nickel and silver cadmium oxide. In normal use, these tips may show slight brown or black tarnish. If the atmosphere around the starter contains high moisture and sulphur, the contact tips will show excessive tarnishing. To clean the contact tips, use this maintenance procedure: 1. Rub the contact tips lightly with fine emery paper. DO NOT FILE THE CONTACT. 2. Remove small particles by rubbing with wet cotton wool or with a wet, clean cloth. 3. Remove the water on the contact tip surface with a dry, clean cloth. If possible, apply acetone or carbon terachloride. Do not use petrol. The maintenance procedure is necessary only if contact tips are covered' with thick, black tarnish film. If the contact tip is uneven, but not heavily tarnished, do not disturb the contact. Contact replacement Contact replacement becomes necessary if less than one- third of the original contact tip remains on the contact. This can be ascertained by comparing the contact with a new one of the same starter. When replacing contacts, change contact springs and leaf springs, if any. Note : Proper soldering of aluminium cables requires special grade of solders and fluxes meant for that purpose. Normal solders and fluxes will produce a joint deceptively acceptable but It will in practice lead to over-heating and eventually to burnouts. L&T SWITCHGEAR SAFE & SURE 58 E S P SERVICE MANUAL S E C T I O N VIII Trouble shooting chart for starters Given below are some of the common complaints in starters. The probable cause and suggested remedy are also given. But before attending to any complaint, ensure that the wiring is as per the wiring diagram given in this booklet. Most of the complaints can be traced to the wiring carried out at the site. FOR DOL STARTERS : Complaint Reasons / Solutions 1. Motor does not start even though 'Start' button is pressed. However on lifting the moving magnet manually, motor starts. 1) a) Coil does not get energised (see control wiring diagram) b) Check nylon strip on relay, Check nylon button below start button. 2. Relay/coil has been charged. However motor does not start when green button is pressed. 2. Check if red wire on the relay and black wire on the coil are properly connected. 3. Motor starts when green button is pressed. It however stops immediately when it is released. 3. a) Blue wire is not connected properly or completely absent, b) Hold-on contact moving strip is missing or improperly placed. 4. Humming and/or chattering noise. 4. a) Low supply voltage b) Magnet faces unclean. Moving system functioning is obstructed by dirt. 5. Use of starters on 230V 10 supply. Incoming / outgoing lines wired. However motor does not start. 5. Coil obtains supply from across R & B supply. However if in/out wires are connected on R & Y phases coil will not energise. You may connect all three phases in series. 6. Remote start/stop button not working properly; motor starts on remote start; however does not stop on remote stop. 6. Red wire not wired as per wiring diagram. L&T SWITCHGEAR SAFE & SURE 59 E S P SERVICE MANUAL 7. Thermostat/float switch/pressure switch are wired to the starter. Motor cannot be stopped properly. Motor stops on pressing stop button. However it restarts on releasing the same. 7) No mistake in wiring here However it is necessary that the stop button is of the stay-put type or locked in.Off position Alternatively, you could shut the main switch. 8. Motor does not restart immediately after tripping on O/L even though resetting has been resorted to. 8) It takes a little time for the thermal bimetals to coil and reset. Hence wait for 2-4 minutes before restarting. FOR STAR-DELTA STARTERS : 1. Motor works in Star. However it does not work properly In Delta and refuses to take load. 1. Check if only three wires are being terminated in terminal box of motor. Six wires should be connected to starter. If shorting links are present they should be removed. 2. a) Motor starts with difficulty in Star or trips when additional load is present, b) Motor works in Star. However stops when Delta connection comes on. 2. Reduce time delay from Star to Delta in case it is kept very long. a) Or if a semi-automatic starter is being used, switch over from Star to Delta earlier than done previously. b) Possibly due to low system voltage. 3. a) Even though all six wires have been connected, motor stops when in Delta, b) Motor stops when in Delta, starter trips and fuse blows. 3. a) Delta connection from motor is improper. b) Low system voltage. Star/Delta connection in starter wrongly connected. 4. Relay has been changed in semi-automatic starter, however when the main switch is on, the motor starts immediately without the necessity of pressing the start button. Motor stops in Star itself. 4. This is a usual complaint. You may have changed the original relay yourself. All factory made relays have loop-wires 2-3 wired, in semi-automatic starters. 2-4 terminals on relays must be connected. Check relay before connecting it on starter. L&T SWITCHGEAR SAFE & SURE 60 E S P SERVICE MANUAL INSTALLATION & COMMISSIONING OF THE MOTOR CONTROLLER MU-G10 AND MU-G20 This controller is provided with several protection features and indicating instruments for the convenience of operation and safety. The motor can be set to start (automatically) within 30-60 secs. after supply is restored. For this, the rocker switch on SPPR has to be set to "AUTO", otherwise set to "BY-PASS" mode. This feature is by-passed as supplied from the factory. The motor controller is armed with the following protection features: 1. Overload protection 2. Phase failure* 3. Phase unbalance * 4. Phase reversal * 5. Dry run protection (Not Standard)* * - Protection features enabled only in AUTO mode and not in BY-PASS mode. Visual indication is provided : 1. Supply Voltage (Line) 2. Current drawn by motor (Phase) 3. Lamp-indicating supply ON 4. Lamp - indicating motor ON For normal operation (manual mode) motor can be switched ON-OFF with GREEN & RED push buttons. Toggle switch should be in ON position. However, please note that the standard RED push button will not function in "AUTO" mode & toggle switch has to be used for switching OFF. By taking these few precautions and care the starter will be able to perform satisfactorily year after year. installation & Commissioning of the motor controller MU-G10 and MlU-G20 A) Installation instruction: • Ensure that the enclosure is mounted in the vertical position. • Set the rocker switch on the SPPR to "BY-PASS" mode, the switch can be set to "Auto" mode only after ensuring the proper operation of the motor for a few minutes. • Use right size of the cables with cable lugs. Use cable glands for fixing cables to the enclosure to avoid excess stress on terminals. • Connect the supply (Line) cables on the terminal block provided, Marked "Supply terminals" in star-delta controller and in DOL controller on the MU contactor. • Connect the motor terminals on the terminal block provided, marked "Motor terminals". L&T SWITCHGEAR SAFE & SURE 61 E S P SERVICE MANUAL • Ensure that the termination joints are properly tightened. • Set the relay pointer corresponding to the actual current drawn by the motor, as indicated by the ammeter. In star-delta controller, the relay setting (phase current) should be reduced to 1 /1.732 times of the ammeter reading (line current) B) Commissioning • Keep the toggle switch in OFF position & SPPR in "By-Pass" mode: • Switch ON the power supply. The RED lamp will be switched ON indicating the presence of the power supply, the actual voltage can be read in the voltmeter (select the phase using the selectorswitch provided.) • Now put the Toggle switch in ON position. • Press the START button. The Green LED lamp should glow and the motor should start. • Ammeter will show the line current drawn by the motor. • For starting the motor automatically after the supply is restored set the switch on the SPPR in "AUTO" mode. The motor will start after a delay of 30-60 secs. In this mode the motor can be switched OFF by the toggle switch - Not by the red button. Star Delta Motor Controller Troubleshooting PROBLEM CAUSE SOLUTION 1. Motor runs in reverse direction Phase sequence not correct Interchange the supply sequence 2. Motor runs in correct direction but stops immediately Motor overloaded Relay tripping Check the current & increase the relay setting appropriately 3. Motor not starting SPPR trips sensing wrong sequence (lamp dosn't glow) Low supply voltage Interchange Y&B on the SPPR Single phasing SPPR trips Phase is unbalanced SPPR trips Wait till proper supply is restored Wait till proper supply is restored Wait till proper supply is restored L&T SWITCHGEAR SAFE & SURE 62
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